Europe is the largest market for biopolymers, with 60% of total production centered there. Average global growth is 12.6% pa, and the overall market is expected to grow from 65000 MT in 2005 to 100000 MT in 2010. Most of that usage will still be in two applications: compost bags and loose-fill packaging.
High expectations for biopolymer markets are required to be viewed with respect to commercial realities. Efforts are focused on boosting mechanical and thermal properties so that biopolymers can be effective alternatives to less costly commodity materials. The constant high speed of development of new bio-materials and applications continues to meet the practical obstacles that hinder their growth such as high prices, limited production capacity and the lack of an infrastructure for effective composting (particularly in North America). Despite setbacks, new materials and modifying agents are expanding the reach and application of biopolymers, particularly in the case of polylactic acid (PLA). Among the new developments discussed at Plastics Technology's recent Conference, are PLA foam grades for thermoformed meat trays, new additives for greater strength and reduced degradation, and fiber-reinforced materials that will expand biopolymers' reach into blow molded bottles.

Slower-than-expected acceptance of biopolymers seemingly contradicts the escalating interest from both consumers and manufacturers in renewable resources, sustainable packaging and reduced dependence on fossil fuels. Market analysts assumed that production and public acceptance of biopolymers would increase and prices would fall to a level competitive with petrochemical based polymers. It has not happened, even in Europe, where growth is the strongest. In USA, PLA prices have fallen, but are still in the range of about US$2-2.2/kg. They are not yet competitive with commodity thermoplastics. Greater U.S. acceptance of biopolymers hinges on development of a composting infrastructure and increased landfill costs to encourage composting.

Limited production capacity for today's best-known biopolymer, PLA, is also a looming concern. The main domestic producer, Nature works' 150000 metric tpa is sold out. Still, the number of researchers, packagers, and processors working with PLA has climbed dramatically the last two years, and applications are multiplying.
Considerable activity is focused on PLA because of its early commercial success and adoption by retailers like Wal-Mart. Much of current R&D seeks to boost PLA's performance profile and match its properties to commodities such as polystyrene. Natureworks is working with two processors to develop the first thermoformed trays of PLA foam in North America. Foamed containers would expand PLA's penetration in rigid packaging beyond clear, thermoformed containers for fresh produce, baked goods, and deli foods.
A key ingredient in the low-density foam grades is a chain-extender additive called CESA-extend from Clariant. At 0.4% to 0.7% loadings, this masterbatch significantly raises PLA's intrinsic viscosity (I.V.) and melt strength, which are the two major limitations.
Thermoformed PLA foam meat trays have already been introduced in Europe by Coopbox Europe SpA of Reggio Emilia, Italy, a leading producer of foam packaging for fresh foods. Its Naturalbox packaging, made of NatureWorks PLA, can be used in standard packaging lines with stretch films or sealed with PLA film for a 100% biodegradable solution.

Recent development work conducted by the National Nutraceutical Center at Clemson Univ. demonstrates that natural fibers such as cotton can be blended with PLA to produce compounds for injection-blow molded bottles. The formulation also includes a small amount of herbs including turmeric, which reportedly boosts UV resistance 45% higher than that of PET. The bottles also boast low moisture and oxygen transmission.
Two new impact modifiers from Arkema almost double the toughness of PLA.
A new biodegradable antioxidant for PLA has also been developed. The product is claimed to protect PLA from heat degradation better than competitive antioxidants. The new material, initially developed at the Univ. of Mass. at Lowell, reportedly also gives PLA three to four times better shelf life. It is expected to be commercialized later this year.
More new additives are being introduced to boost PLA's processability and performance.