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PRESENTED BY:- HASAN IJTABA KHAN MAFTUN 09-PE-12 FAISAL NADEEM 09-PE-07 KHAWAJA OWAIS KAMAL 09-PE-14 SYED HASSAN SAEED 09-PE-34 AHMED IMRAN QUREISHI 09-PE-03 MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

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MANUFACTURING OF BIODEGRADABLE POLYETHYLENE. PRESENTED BY:- HASAN IJTABA KHAN MAFTUN09-PE-12 FAISAL NADEEM09-PE-07 KHAWAJA OWAIS KAMAL09-PE-14 SYED HASSAN SAEED09-PE-34 AHMED IMRAN QUREISHI09-PE-03. BIODEGRADATION. - PowerPoint PPT Presentation

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Page 1: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

PRESENTED BY:-

HASAN IJTABA KHAN MAFTUN09-PE-12

FAISAL NADEEM 09-PE-07KHAWAJA OWAIS KAMAL 09-PE-14SYED HASSAN SAEED 09-PE-34AHMED IMRAN QUREISHI 09-PE-03

MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

Page 2: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

BIODEGRADATION BIODEGRADATION

Process by which organic substances are broken down by the environmental effects and by the living organisms.

Organic material can be degraded aerobically

or anaerobically .

Biodegradable matter is generally organic material such as plant and animal matter and other substances originating from living organisms, or artificial materials that are similar enough to plant and animal matter to be put to use by microorganisms.

Biodegradable polymers are a kind of materials which degrades biologically.

The biodegradability of plastics is dependent on the chemical structure of the material and on the constituent of the final product, not just on the basic materials used in the production.

Page 3: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

THE RANGE OF BIODEGRADABLE PLASTIC THE RANGE OF BIODEGRADABLE PLASTIC

Starch based products including thermoplastic starch, starch and synthetic aliphatic polyester blend, and starch and PVOH (polyvinyl alcohol) blends.

Naturally produced polyester including PVB (polyvinyl butadiene).

Renewable resource polyesters such as PLA (poly lactic acid).

Synthetic aliphatic polyesters including PCL (poly caprolactone).

Aliphatic-aromatic (AAC) co polyester.

Hydro-biodegradable polyester such as modified PET.

Water-soluble polymers such as polyvinyl alcohol and ethylene vinyl alcohol.

Photo-biodegradable plastics.

Controlled degradation additive master batches.

Page 4: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

CLASSES OF BIODEGRADABLE PLASTICSCLASSES OF BIODEGRADABLE PLASTICS

Compostable

Hydro-biodegradable

Photo-biodegradable

Bioerodable

Biodegradable

Page 5: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

BACKGROUND OF STARCH-BASED POLYMERS

BACKGROUND OF STARCH-BASED POLYMERS

Our work relates to a biodegradable film prepared by chemical bonding of starch and polyethylene.

Polyethylene is polyolefin having the most widest general application, coupling agent such as maleic anhydride, methacrylic anhydride or maleimide which bonds with starch and polyethylene, and Lewis acid catalyst and to a process for preparing thereof.

Page 6: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

BACKGROUND OF STARCH-BASED POLYMERS

BACKGROUND OF STARCH-BASED POLYMERS

Starch

Chemical formula of starch (C6H10O5)n

Starch is a linear polymer (polysaccaride) made up of repeating glucose groups linked by glucosidic linkage in the 1-4 carbon position.

The length of the starch chain will vary with plant sources but in general the average length is between 500-20,000 glucose units.

There are actually two types of starch molecules: – Amylose – Amylopectin.

The only difference between the two is the arrangement of the molecules.

Amylose is essentially linear while amylopectin has many branches like a tree.

Page 7: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

CHEMISTRY OF STARCH CHEMISTRY OF STARCH

Amylose

– Amylose molecules consist of single mostly-unbranched chains with 500-20,000 α-(14)-D-glucose units dependent on source.

– Hydrogen bonding between aligned chains causes retro gradation

and releases some of the bound water.

Page 8: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

CHEMISTRY OF STARCH CHEMISTRY OF STARCH

Amylopectin

– Amylopectin is formed by non-random α-16 branching of the amylose-type α-(14)-D-glucose structure.

– Each amylopectin molecule contains a million or so residues.

– Each amylopectin molecule contains up to two million glucose residues in a compact structure with hydrodynamic radius 21-75 nm.

Page 9: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

VARIETIES OF STARCHVARIETIES OF STARCH

Page 10: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

VARIETIES OF STARCHVARIETIES OF STARCH

Corn Starch

– Common cornstarch has 25% amylose. The two remaining

cornstarches are high-amylose cornstarches;

one has 50% to 55% amylose, while the second

has 70% to 75%. Their size ranges between 5 microns and 20 microns

Maize Starch

– Maize starch has irregularly shaped granules.

High-amylose starches also have an irregular shape, but tend to be smooth. Some of these are even rod-shaped. High-amylose starches have a narrower size range: 5 to 15 microns, or even 10 to 15 microns, depending on the variety.

Page 11: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

VARIETIES OF STARCHVARIETIES OF STARCH

Potato Starch

– Potato starch has about 20% amylose. Potato starch granules are large with a smooth round oval shape. Of the starches commonly used for food, potato starch is the largest; its granules range in size from 15 to 75 microns.

Rice Starch

– Common rice starch has an amylose: amylopectin ratio of about 20:80, while waxy rice starch has only about 2% amylose. Both varieties have small granule sizes ranging from 3 to 8 microns.

Page 12: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

VARIETIES OF STARCHVARIETIES OF STARCH

Tapioca Starch

– Tapioca starch has 15% to 18% amylose. Tapioca granules are smooth, irregular spheres with sizes ranging from 5 to 25 microns.

Wheat Starch

– Wheat starch has an amylose content of around 25%. Its granules are relatively thick at 5 to 15 microns with a smooth, round shape ranging from 22 to 36 microns in diameter.

Soya bean Starch

– Soya bean starch has irregular shaped granules. Common Soya bean starch has 7% amylose. Its granules range in size from 10 to 90 microns.

Page 13: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

VARIETIES OF STARCHVARIETIES OF STARCH

Page 14: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

CATEGORIES OF STARCH BASED POLYMERS

CATEGORIES OF STARCH BASED POLYMERS

Thermoplastic starch products.

Starch synthetic aliphatic polyester blend

Starch PBS/PBSA polyester blends

Starch PVOH blends.

Page 15: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

CATEGORIES OF STARCH BASED POLYMERS

CATEGORIES OF STARCH BASED POLYMERS

Thermoplastic Starch Products

– Thermoplastic starch biodegradable plastics (TPS) have a starch (amylose) content greater than 70%.

– It is based on vegetable starch, and with the use of specific plasticizing solvents, can produce thermoplastic materials with good performance properties and inherent biodegradability.

– This can be overcome through blending, as the starch has free hydroxyl groups, which readily undergo a number of reactions such as acetylation, esterification and etherification.

Page 16: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

CATEGORIES OF STARCH BASED POLYMERS

CATEGORIES OF STARCH BASED POLYMERS

Starch Synthetic Aliphatic Polyester Blends

– Blends of biodegradable synthetic aliphatic polyesters and starch are often used to produce high quality sheets and films for packaging by flat-film extrusion using chill-roll casting or by blown film methods

– Approximately 50% of the synthetic polyester (at approximately $4.00/kg) can be replaced with natural polymers such as starch (at approximately $1.50/kg), leading to a significant reduction in cost.

– Furthermore, the polyesters can be modified by incorporating a functional group capable of reacting with natural starch polymers.

Page 17: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

CATEGORIES OF STARCH BASED POLYMERS

CATEGORIES OF STARCH BASED POLYMERS

Starch and PBS/PBSA Polyester Blends

– Polyesters that are blended with starch to improve material mechanical properties are Polybutylene succinate (PBS) or polybutylene succinate adipate (PBSA).

– At higher starch content (>60%), such sheets can become brittle.

– Plasticizers are often added to reduce the brittleness and improve flexibility.

– Starch and PBS or PBSA blends are used to produce biodegradable plastic sheet, which can be thermoformed into products such as biscuit trays or film products.

Page 18: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

CATEGORIES OF STARCH BASED POLYMERS

CATEGORIES OF STARCH BASED POLYMERS

Starch-PVOH Blends

– Polyvinyl alcohol (PVOH) is blended with starch to produce readily biodegradable plastics.

Page 19: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MARKET SURVEY REPORT MARKET SURVEY REPORT

Page 20: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MARKET ANALYSIS OF BIODEGRADABLE MATERIAL

MARKET ANALYSIS OF BIODEGRADABLE MATERIAL

– The technology surrounding biopolymers and biodegradable packaging has been in the development stage for the last 15-20 years.

– In the last five years have markets developed and much commercial growth been seen.

– Only few companies are currently producing biodegradable packaging materials on a large enough scale to be commercially successful.

Page 21: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

NUMBER OF COMPANIES WITH BIODEGRADABLE PLASTICS

NUMBER OF COMPANIES WITH BIODEGRADABLE PLASTICS

Figure illustrates the trend, showing that the number of companies applying for patents increased through the 1990s and appears to have peaked in 2005.

Page 22: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

BIODEGRADABLE MATERIAL’S MARKET OVERVIEW

BIODEGRADABLE MATERIAL’S MARKET OVERVIEW

Figure Identifying the top 30 companies listed as first assignee indicates which companies are most active in patenting new technologies and processes.

According to the Rapra report, 30 suppliers are currently active in the global biopolymer market, with BASF, DuPont and Mitsubishi Gas Chemicals dominating.

Novamont and Mitsubishi are also found among the patent leaders, suggesting that competition could heat up over the next few years.

Page 23: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

GEOGRAPHICAL DISTRIBUTION OF PATENT ACTIVITY FOR USE OF BIODEGRADABLE MATERIALS

GEOGRAPHICAL DISTRIBUTION OF PATENT ACTIVITY FOR USE OF BIODEGRADABLE MATERIALS

Following figure shows that nearly half of the filings examined were published in the United States (USPTO).

The other half is divided among World patents (WIPO), European patents, Japanese and British patents.

Page 24: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

ACTIVE SUPPLIERS OF BIODEGRADABLE MATERIAL

ACTIVE SUPPLIERS OF BIODEGRADABLE MATERIAL

Proctor and Gamble Limited. BASF Germany. DuPont. Mitsubishi Gas Chemicals. Nova Mont. Nature Works. Rodenburg Biopolymers. Biotech. Mitsubishi. Merck Chemicals.

Page 25: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

LOCAL MARKET SURVEYLOCAL MARKET SURVEY

We have conducted local market survey and have reached to the conclusion that the biodegradable material is not available in the market.

We also have contacted the following companies and the results are the same as mentioned above.

– Bin Rasheed – Umair Petrochemicals– MERCK Chemicals– P & G Pakistan – BASF Pak Ltd.

Page 26: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

LOCAL MARKET SURVEYLOCAL MARKET SURVEY

a.DENSO HALL SADDAR KARACHI

NAME PERSON CONTACTED

ADDRESS

BISMILLAH PLASTICS

Deals in all kinds of plastic raw

materials and waste.

Mr. M Asif Abdul Sattar

Shop No 1-2-B, Noori center, 1/98, Khachi Gali No-2, Marriott RoadTel:- 0092-21-7085200Cell:- 0092-322-2872835

SATTAR PLASTICSPurchasers and

sellers of all kinds of plastic waste and

powder.

Mr. Mohammad Siddique

Mr. Umair SiddiqueMr. Abdul Rehman

Shop No-1 Moonpur Wala Center Kutchi Gali No-2 Marriott RoadTel:-0092-21-2435892 0092-21-2434071Cell:-0092-300-2104966 0092-321-8297514E-mail:[email protected]

b) LIAQUATABAD KARACHI

NAME PERSON CONTACTED

ADDRESS

AYUB PLASTICSDeals in all kinds of

powder and scrap, sale and purchasing.

Mr. M Ayub Raza

Shop No 14, B-Road near Police Station Liaquatabad Tel:- 0092-21-4914687 0092-21-4854754Cell:-0092-333-2192847

PLASTIC MARKAZDeals in all kinds of

plastic sale and purchase.

Mr. M Alam Shop No-32 Commercial Area B-Road Dakkhana Karachi Tel:- 0092-21-4917872 Cell:-0092-300-2197630

MAHBOOB PLASTICSSpecialist in all kinds

of plastic material sales and purchase

Mr. Mateen Khan Shop No-29 “B”-Road Liaquatabad KarachiTel:- 0092-21-4920314Cell:-0092-333-2307411

INTERNATIONAL PLASTIC POINT

Deals in all kinds of plastic materials.

Mr. Shafiq Ahmed 233-B, Road Liaquatabad KarachiTel:-0092-21-4120798Cell:-0092-346-2716744

Page 27: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

DISPOSAL ENVIRONMENTS DISPOSAL ENVIRONMENTS

Page 28: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

Composting facilities or soil burial

Anaerobic digestion

Wastewater treatment facilities

Plastics reprocessing facilities

Landfill

Marine and freshwater environments

General open environment as litter.

Page 29: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

COMPOSTING FACILITIES AND SOIL BURIAL

– Composting and soil burial is the preferred disposal environment for most biodegradable plastics.

– The degradation mechanism of biodegradable plastics in a composting environment is primarily hydrolysis combined with aerobic and anaerobic microbial activity.

– Typically for full degradation, composting occurs over a 10 to 12 week period.

– The degradation products of aerobic composting are compost and CO2.

Page 30: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

ANAEROBIC DIGESTION

– Anaerobic digestion is also gaining support as an alternative to

landfills.

– Methane production may be faster, more efficient and more predictable in this system and a useful end-product, compost, is also produced.

Page 31: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

WASTE WATER TREATMENT PLANTS

– Activated sewage sludge will convert approximately 60% of a biodegradable polymer to carbon dioxide.

– The remaining 40% will enter the sludge stream where, under anaerobic digestion, it will be converted to methane.

– Any biodegradable polymer that meets the compostability criteria will degrade even faster in a sewage environment.

Page 32: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

REPROCESSING FACILITIES

It is to be expected that if biodegradable plastics began to occupy a significant market share of the plastics market in the world that some material would end up in plastics reprocessing facilities. This could have significant effects on the sorting procedures required and the quality of recycled end products.

Page 33: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

LANDFILLS

– When conventional low-

density polyethylene film

was under bioactive soil

for almost 40 years, the

surface of the film shows

signs of biodegradation

with the molecular weight dropping

by half the original.

– The inner part of the sample was almost unchanged with the molecular

weight being retained.

Page 34: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

LANDFILLS

– Environmentally degradable polymers could increase the capacity of landfill sites by breaking down in a relatively short time and freeing other materials for degradation, such as food scraps in plastic bags.

– Typical landfill gas contains 50% methane and 45% CO2, with the

balance composed of water and trace compounds.

Page 35: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MARINE AND FRESHWATER ENVIRONMENTS

The rate of biodegradation in marine environments is affected by the water temperature.

– In cold waters, the plastic material may still be in a form that

could endanger marine life for an extended period of time. It is found that plastic is fully degraded in 20-30 days in a compost environment .

– Thus seasonal and climatic effects on biodegradation rates need to be considered in relevant applications.

Page 36: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

MAJOR DISPOSAL ENVIRONMENTS FOR BIODEGRADABLE PLASTICS

LITTER

Plastic litter causes aesthetic problems as well as danger to wildlife resulting from entanglement and ingestion of plastic packaging materials and lightweight bags. Wildlife losses are an issue for the conservation of biodiversity, and losses due to litter have caused public concern.

Page 37: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

PROCEDURE OF MANUFACTURING STARCH BASED POLYETHYLENE

PROCEDURE OF MANUFACTURING STARCH BASED POLYETHYLENE

Page 38: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

BIODEGRADABLE POLYETHYLENE COMPOSITION CHEMICALLY BONDED

WITH STARCH

BIODEGRADABLE POLYETHYLENE COMPOSITION CHEMICALLY BONDED

WITH STARCH

Contents Amount

Polyethylene 100 parts by weight

Biodegradable incorporating material{Selected from the group consisting of

corn starch, acid treated starch, esterifies starch, etherified starch,

cationic starch and mixtures}

5 - 400 parts by weight

Coupling agent {Selected from the group consisting of

maleic anhydride, methacrylic anhydride and maleimide}

0.01 - 10 parts by weight

Lewis acid catalyst 0.01 - 6 parts by weight

Radical initiator 0.01 - 1.0 parts by weight

Autoxidizing agent 0.01 - 10 parts by weight

Plasticizer 0.01 - 10 parts by weight

Page 39: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

BIODEGRADABLE POLYETHYLENE COMPOSITION CHEMICALLY BONDED

WITH STARCH

BIODEGRADABLE POLYETHYLENE COMPOSITION CHEMICALLY BONDED

WITH STARCH

In this composition the polyethylene is selected from the group consisting of low density polyethylene LDPE. The LDPE which we have selected for our biodegradable starch based film is PETLIN-MALAYSIA of extrusion grade.

The radical initiator may be di-cumyl peroxide.

The Autoxidizing agent is one or more selected from the group consisting of manganese oleate, manganese stearate, ferrous oleate (II). Since we were unable to find autoxidizing agent due to its unavailability in the market, so as per our advisor recommendation we have not used autoxidizing agent in our formulation.

The Lewis acid catalyst is one from the group consisting of stearic acid and acetic acid . We have used stearic acid as a catalyst in our formulation.

The plasticizer is one selected from group consisting of oleamide, Viton poly (hexaflouropropylene)-copoly (vinylidene fluoride) or Erucamide Cis-13-1-docosenoamide. In our formulation we have not used plasticizer due to its unavailability in the local market.

Page 40: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

PROPOSED RATIO OF POLYETHYLENE AND STARCH

PROPOSED RATIO OF POLYETHYLENE AND STARCH

POLYETHYLENE RAFHAN MAIZE STARCH

PERCENTAGE PERCENTAGE

80 20

60 40

Page 41: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

COMPATIBILTY OF LDPE WITH DIFFERENT TYPES OF STARCHES

COMPATIBILTY OF LDPE WITH DIFFERENT TYPES OF STARCHES

Starch Temperature o C

Pressure

Psi

Time

Minutes

Compatibility Melting Point

o C

Microscopic View

Maize Starch

230 110 20 Yes 265

Wheat Starch

230 110 20 No 285

Corn Starch

230 110 20 No 280

Page 42: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

PROJECT DESCRIPTIONPROJECT DESCRIPTION

Initially we have been suggested to make a starch based biodegradable polyethylene blown film through single screw extruder.

Afterwards the management of PLASTICS TECHNOLOGY CENTRE proposed us to manufacture a strip of starch based biodegradable polyethylene by using a profile die on BRABENDER PLASTICORDER.

Page 43: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

FORMULATION FOR BRABENDERFORMULATION FOR BRABENDER

CONTENTS STANDARDS 250gms FORMULATIO

N

250gms FORMULATIO

N

PHR 80/20 Ratio 60/40 Ratio

LDPE 100 199 gms 149 gms

Maize Starch 5-400 50 gms 100 gms

Maleic Anhydride

0.01-10 0.25 gms 0.25 gms

Stearic Acid 0.01-06 0.25 gms 0.25 gms

Di-Cumyl Per Oxide

0.01-1.0 0.25 gms 0.25 gms

Manganese Stearate

0.01-10 N/A N/A

Viton 0.01-10 N/A N/A

Page 44: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

MIXINGMIXING

Mixing of the above two proposed formulation is carried out in a HANSCHEL MIXER for about 15 minutes.

Before putting the material in the mixer for mixing, the mixer should completely and thoroughly be cleaned with a clean cloth so as to avoid contamination of the two proposed batches.

Page 45: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

PROCESSING AT BRABENDER PROCESSING AT BRABENDER

After mixing, the compound has been taken to the BRABENDER PLASTICORDER.

Profile die is used and the extrudate is manually cut with the help of a cutter to have it in a shape of a strip.

Initially the BRABENDER is operated to remove the last traces of the material left in the barrel in the last processing operation.

Once all the old material’s been removed, virgin LDPE has been added through the hopper to achieve the required temperature.

Since we were processing starch with LDPE for the first time in our carrier, we were stock feeding the machine so that the material should not block the nozzle of the machine.

Fans in the processing hall were kept closed to achieve the desired temperatures on the machine.

Page 46: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

PROCESSING AT BRABENDERPROCESSING AT BRABENDER

Firstly we processed 80/20 ratio formulation so as to check the behavior of the machine with the starch incorporated batch.

After the production of 80/20 ratio batch, we processed pure LDPE so as to clean the barrel of the extruder for next formulation.

For 60/40 ratio formulation, the temperatures

at the machine are slightly increased as the

content of starch is greater as compared with

the previous composition. Once the desired

temperature range has been achieved,

the strips of the proposed formulation have

been produced.

Water bath has been used immediately after the die so as to cool the formed product.

Page 47: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

PROCESSING PARAMETERS AT BRABENDER

PROCESSING PARAMETERS AT BRABENDER

PARAMETERS 80/20 RATIO 60/40 RATIO

Size of the Batch 249.75 grams 249.75 grams

Temperature at Feeding Section

210 o C 230 o C

Temperature at Compression Section

215 o C 230 o C

Temperature at Metering Section

190 o C 215 o C

Die Temperature 190 o C 210 o C

Screw Speed 35 RPM 35 RPM

Die Shape Profile Die Profile Die

Time Consumed 4 Hours 4 Hours

Page 48: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

TESTINGTESTING

Page 49: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

INTERNATIONAL ORGANISATIONS FOR STANDARDS AND TEST METHODS

INTERNATIONAL ORGANISATIONS FOR STANDARDS AND TEST METHODS

American Society For Testing And Materials (ASTM)

European Standardization Committee (CEN)

International Standards Organisation (ISO)

Institute for Standards Research (ISR)

German Institute for Standardization (DIN)

Organic Reclamation and Composting Association (ORCA) (Belgium)

Page 50: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

DIFFERENCE BETWEEN STANDARDS FOR BIODEGRADATION

DIFFERENCE BETWEEN STANDARDS FOR BIODEGRADATION

STANDARD BIODEGRADATION REQUIREMENTS

DIN 60 % 6 Months

ASTM 60 % 6 Months

CEN 90 % NIL

ORCA 60 % (for chemicals) 28 Days

Page 51: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

TENSILE STRENGTHTENSILE STRENGTH

Machine = Instron-4302 Universal Testing Machine UTM

Load = 01 KN

Sample Clamping = Pneumatic

Testing Length (GL) = 25 mm

Speed = 50 mm / min

Page 52: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

80/20 FORMULATION80/20 FORMULATION

SAMPLE AREA FORCE AT PEAK ELONGATION AT PEAK

W X T LOAD EXTENSION

01 4.05x1.8=7.29mm 2.046 Kgf 2.62 x 4 =10.48 %

02 4.10x1.95=7.99mm 1.895 Kgf 2.54 x 4 = 10.16 %

03 4.10x2.0 =8.2mm 2.132 Kgf 4.68 x 4 = 18.72 %

04 4.05x2.0=8.1mm 2.070 Kgf 2.94 x 4 = 11.76 %

05 4.05x1.95=7.89mm 2.244 Kgf 4.11 x 4 = 16.44 %

06 4.05x2.0=8.1mm 0.5396 Kgf 1.97 x 4 = 7.88 %

07 4.2x201=8.8mm 2.040 Kgf 3.69 x 4 = 14.76 %

08 4.05x2.0=8.1mm 1.981 Kgf 4.72 x 4 = 18.88 %

Page 53: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

60/40 FORMULATION60/40 FORMULATION

SAMPLE AREA FORCE AT PEAK ELONGATION AT PEAK

W X T LOAD EXTENSION

01 4.15x1.05=4.357mm 1.407 Kgf 5.30 x 4 = 21.2%

02 4.15x0.95=3.94mm 0.7007 Kgf 3.90 x 4 = 15.6%

03 4.15x0.9=3.73mm 0.8859 Kgf 4.12 x 4 = 16.48 %

04 4.2x0.7=2.94mm 0.6497 Kgf 2.93 x 4 = 11.72 %

05 4.2x0.9=3.78mm 1.219 Kgf 4.14 x 4 = 16.56 %

06 4.2x0.75=3.15mm 0.8349 Kgf 3.69 x 4 = 14.76 %

07 4.15x1.0=4.15mm 1.323 Kgf 4.75 x 4 = 19 %

08 4.2x0.9=3.78mm 1.216 Kgf 4.37 x 4 = 17.48 %

Page 54: MANUFACTURING OF BIODEGRADABLE POLYETHYLENE

DENSITY TESTDENSITY TEST

MATERIAL DENSITY

Grams/cubic centimeter

Pure LDPE 0.915

80/20 Ratio N/A

60/40 Ratio 0.929

Machine = Electronic Densimeter SD-120LUnits = grams / cubic centimeter

The density of 80 / 20 ratio cannot be found as the material was unable to flow through the die of melt flow index (MFI).

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MELT FLOW INDEXMELT FLOW INDEX

Machine = Melt Flow Index (MFI) Davenport

Load = 2.16 Kg

Cut of Time = 3 minutes

Units = grams / 10 minutes

Feed in = 3 – 5 grams

Factor = 3.33

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PURE LDPE MFIPURE LDPE MFI

SAMPLE WEIGHT

Grams / 10 minutes

01 0.891

02 0.833

03 0.827

04 0.867

05 0.854

Mean Value 0.8544

MFI = Mean Value x FactorMFI = 0.8544 x 3.33

MFI = 2.5623 grams / 10 minutes

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80 / 20 RATIO MFI80 / 20 RATIO MFI

The MFI of 80 / 20 ratio batch cannot be done as the material was not flowing through the die of MFI.

Flakes of 80 / 20 ratio for MFI

Extrudate of 80 / 20 formulation

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60 / 40 RATIO MFI60 / 40 RATIO MFI

SAMPLE WEIGHT

Grams / 10 Minutes

01 0.48

02 0.462

03 0.498

04 0.49

05 0.495

Mean Value 0.485

MFI = Mean Value x Factor

MFI = 0.485 x 3.33 MFI = 1.61505 grams / 10 minutes

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BURY TESTBURY TEST

The strips of both the batches of starch based biodegradable polyethylene are buried in soil with the cow dung. The ratio of the soil and the cow dung is 50: 50. Cow dung is used to make the production of the microorganisms faster. It will fasten the biodegradation process. 15 cm sample of both the formulation are buried in the mixture of soil and the cow dung. The mixture is placed in the open sun for next three months.

The strip of biodegradable composition will be obtained after three months and will be taken into observation for the mechanical tests.

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MELTING POINTMELTING POINT

FORMULATION MELTING TEMPERATURE

PE / Starch o C

80 / 20 220

60 / 40 255

Machine = Hot Stage Microscope

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PROS AND CONS OF STARCH BASED BIODEGRADABLE POLYETHYLENE

PROS AND CONS OF STARCH BASED BIODEGRADABLE POLYETHYLENE

PROS

Biodegradable means that, under certain conditions, the material will be degraded into small pieces that can be absorbed by microorganisms and transformed into CO2, H2O, energy and neutral residue.

Reduced fossil fuel content (depending on loading of filler)

Faster degradation of litter

No net increase of carbon dioxide in global ecosystem.

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PROS AND CONS OF STARCH BASED BIODEGRADABLE POLYETHYLENE

PROS AND CONS OF STARCH BASED BIODEGRADABLE POLYETHYLENE

CONS

Degradation in a sealed landfill takes at least 6 months.

Limited Shelf life.

Poorer mechanical strength than additive based example – filling a starch bag with wet leaves and placing it curbside can result in the bottom falling out when a hauler picks it up. However, some biodegradable and compostable films are now very close to polyethylene or polypropylene, depending on the starch used.

Some need to be composted in industrial facilities because the temperature of the compost needs to be at 58°C. Others ( OK-compost) are home composting (temperature 20°C).

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Adapted from Watson 1992

EMERGING APPLICATION AREAS

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EMERGING APPLICATION AREASEMERGING APPLICATION AREAS

COATED PAPER

AGRICULTURE MULCH FILM

SHOPPING BAGS

FOOD WASTE FILMS AND BAGS

CONSUMER PACKAGING MATERIALS

LANDFILL COVER FILMS

OTHER APPLICATIONS

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FUTURE OUTLOOK FOR BIODEGRADABLE PLASTICS

FUTURE OUTLOOK FOR BIODEGRADABLE PLASTICS

It is estimated that plastic waste generation will grow by 15% per year for the next decade.

There is room for growth and expansion in many areas of the biodegradable plastic industry.

Researchers worldwide are interested in the area of biopolymer development.

Organic recovery (composting spent materials) is the most commonly

applied waste reduction method.

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FUTURE OUTLOOK FOR BIODEGRADABLE PLASTICS

FUTURE OUTLOOK FOR BIODEGRADABLE PLASTICS

The nature of natural materials requires different considerations than those for synthetic materials.

The biopolymer industry has a positive future, driven mainly by the environmental benefits of using renewable resource feedstock sources.

The ultimate goal for those working in development is to find a material

with optimum technical performance, and full biodegradability.

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THANK YOUTHANK YOU