High heat injection molding with biopolymers and other developments

High heat injection molding with biopolymers, and other developments

A biopolymer grade aimed primarily at injection molding of semi-durable consumer products has been introduced by NatureWorks LLC. The company introduced its second generation Ingeo� bioresin solution targeted primarily at injection molding of semi-durable consumer products. This new patent-pending solution is the latest in a series of breakthroughs for Ingeo applications, which already include high heat thermoforms, films, and gift and transactional cards. The new compounded resin technology enables the production of injection molded parts with thermal dimensional stability up to 120° Celsius (248° F), notched Izod impact strength greater than two foot-pounds per inch, and modulus of ~ 450,000 psi. Injection molding cycle time compares to styrenic resins, for which the new Ingeo technology now offers a low-carbon, cost-competitive, performance replacement. Designated Ingeo 3801X, the new formulation combines a high percentage polylactide base resin with a tailored additive package designed to achieve the high heat, impact, and cycle time performance requirements of semi-durable products such as cosmetics, consumer electronics, toys, office accessories, and promotional products. Brand owners that replace traditional plastic components with the new Ingeo formulation can reduce their dependence on non-renewable petroleum inputs and lower overall greenhouse gas emissions and energy consumption. Furthermore, brand owners are now able to source a renewable plastic resin that offers a more stable pricing structure relative to the price volatility expected of most petroleum-derived products. An array of injection molded consumer products, with items that include lipsticks and compacts, mobile phones, and auto interior parts has been developed.
Current containers made from corn-based plastics literally cannot take the heat of hot-filling, according to US Department of Agriculture (USDA) chemist William J. Orts. But Orts and a team of collaborators from Lapol, LLC, of Santa Barbara, hope to change that by making corn-derived plastics more heat-tolerant. By boosting the bioplastics' heat tolerance, the collaboration (under way since 2007) may broaden the range of applications for which corn-derived plastics could be used as an alternative to petroleum-based plastics. Corn-based plastics are made by fermenting corn sugar to produce lactic acid. The lactic acid is used to form polylactic acid, or PLA, a bioplastic. The Albany team is developing a product known as a heat-deflection temperature modifier that would be blended with PLA to make it more heat-tolerant. The modifier is more than 90% corn-based and is fully biodegradable. There currently are no commercially available heat-deflection temperature modifiers for PLA. With further research and development, the heat modifier might make it possible for food or beverage bottles or other containers made from PLA to be �hot-filled,� that is, filled at the food-manufacturing or beverage-bottling plant while the food or beverage is still hot from pasteurization. .
Innovia Films has launched its high barrier NatureFlex^TM range of renewable and compostable cellulose-based packaging films for the North American market. The new films, NatureFlex^TM NKR and NKA, provide the highest moisture barriers of any transparent bio-film on the market. It contains over 90% renewable content as measured by ASTM 6866 and is produced from wood pulp sourced from managed plantations which either have or are actively working towards Forest Stewardship Council (FSC) certification or equivalent. The product is also compostable and meets the requirements of ASTM D6400, composting within six weeks. Both these films provide an excellent barrier to gases and aroma, a good barrier to moisture and have a wide heat-seal range. They also offer advantages for packing and converting such as inherent deadfold and anti-static properties, high gloss and they are resistant to grease and oil. They are ideal for packing moisture-sensitive products such as coffee, cookies, condiments, chips, bakery and cosmetics. Types of pack construction the films could be used in include � twist wrap, overwrap, pouches, sachets, lamination with other bio-films, HFFS flow wrap, VFFS bags. .
FKuR Kunststoff GmbH, a German bio-plastics company, has developed, in cooperation with the Fraunhofer Institute UMSICHT, the world�s first sustainable deep freeze packaging made from renewable resources. The basis of this unique film structure is FKuR�s Bio-Flex range of certified compostable bio-films. To highlight their sustainable and ecological image, an increasing number of converters are looking for packaging made from renewable resources which are biodegradable and certified to the ASTM D6400 standard. When considering the performance of deep freeze packaging the material�s mechanical properties at low temperatures are particularly crucial. High impact strength and dart drop strength at these temperatures are a must in order to succeed. Low glass-transition temperatures as well as a homogeneous material with excellent distribution of functional additives are the keys to meeting these requirements. To obtain the film properties required for deep freeze packaging, a three-layer system made from Bio-Flex F 2110 / Bio-Flex A 4100 CL / Bio-Flex F 2110 can be used. This film has a very appealing gloss surface together with great strength and chemical resistance along with demonstrating good barrier properties for a bioplastics. Both resins are based on a blend of PLA and other biodegradable materials. Bio-Flex F2110 as well as Bio-Flex A 4100CL are compostable according to ASTM D6400 and are food contact approved. Bio-Flex F 2110 is a translucent film with very good impact resistance at low temperatures and is especially useful in co-extrusions with other Bio-Flex grades. Its mechanical characteristics are very similar to HDPE. Bio-Flex A 4100 CL represents a specialty amongst bioplastics. It is the first transparent PLA-based blend which can be converted into an excellent blown film. Additionally, the content of material from renewable resources in this grade is outstandingly high. Bio-Flex A 4100 CL is a rather rigid grade and the mechanical characteristics are comparable to those of PP. This material is often used in the packaging of fruit, vegetables and flowers, as well as part of a co-extruded film.