For Greener Future

Potensi Pasar , Proses dan

Komersialisasi Bioplastik

FGD Plastik: Pencemaran dan Solusi, Scralet Hotel Bandung, 2 Mei 2019

by Dr. Asmuwahyu Saptorahardjo

Biopolimer berbahan dasar tepung nabati

BIOBASED BIODEGRADABLE
Biobased-polymer pada bermacam Pati (Starch)

Amylose

Amylopectin

www.enviplast.com | info@enviplast.com
Kapasitas di 2017

www.enviplast.com | info@enviplast.com 4
Di 2018

www.enviplast.com | info@enviplast.com 5
Pasar 2017-
2022 , Globa
 Dibandingkan plastik konvensional,
bioplastik memiliki beberapa keterbatasan:

Lebih rendah di Kekuatan Impak dan

Pemuluran putus
Keterbatasan
Processability: Melt Strength rendah dan
Bioplastik Kemampuan alir rendah.
Biodegradable
Mudah terdegradasi secara thermal

Unjuk kerja hanya pada suhu rendah-sedang

www.enviplast.com | info@enviplast.com 7
 PLA, kaku,
TPS: Fleksibel, mudah
murah dan prosesnya, tapi
mudah didapat laju kristalisasi
Beberapa sifat lambat.
Umum
Bioplastik PVOH ,
PBS, PBSA, PBAT,
transparan dan
Biodegradable PCL memiliki
sangat kaku
mulur putus
tanpa plasticiser
siginificant.
, hydrosoluble
 • Bahan baku yang stabil dari sudut
ketersediaan maupun kualitas: Industrial
based: tepung jagung, tepung tapioka,
tepung tepung tanaman lain, rumput laut,
CPO, limbah cair maupun padat produksi
CPO.
• Processability baik di sisi hilir,
compounding, maupun hulu, conversi
(Blown film, extrusion casting, extrusion
Prinsip profiling, thermoforming, injection
molding, blow molding)
Komersialisasi • Pemahaman sifat polimer yang perlu
diidentifikasi sehingga processability saat
Bioplastik manufacturing , utamanya process-control
dapat terkendali
• Giliranya saat process-control terkendali ,
product performance diterima customer.
• End of Lifenya memenuhi standard yang
ada.
 Komersialisasi Bioplastic
Proses Konversi Berskala Sifat Polimer Utama Contoh Bioplastic
Komersial diatas 12
kg/jam
Press Molding Modulus elasticity Semua
Injection Molding Modulus elasticity,
MeltFlow PLA,
Blown Film Melt Strength, Draw Starch Compound, PBAT,
Down, Melt Flow, PVOH
elongation at yield, Low Tg
Extrusion Profiling Draw Down, Melt Flow, PLA, PBS
Modulus elasticity ,
elongation at yield
Thermoforming Melt Strength, Melt Flow, PLA,
HDT, Hidrophobicity,
Modulus elasticity
Extrusion Casting Melt strength, Low Tg, Starch based, PBAT, PVOH
www.enviplast.com | info@enviplast.com 10
 • Biopolimer , seperti amylosa –amylosa pectin perlu
plasticiser untuk menurunkan Suhu Transisi Gelas
• Biopolimer perlu diformulasi dengan Polimer
sintetik biodegradable
• Butuh compatibiliser antara biopolimer dengan
polimer sintetik . Perlunya penurunan tegangan
permukaan antara fasa.
Pemrosesan • Ukuran partikel powder seseragam mungkin,.
Bahan Baku • Pada kasus pemakaian Biopolimer dengan dasar
karbohidrat, compounding didasari pada proses
Compounding “masak”. Sehingga pembentukan Thermoplastic
Starch didasari pada keberhasilan masak ,
gelatinisasi sempurna. Kristal Starch terkonversi
menjadi amorph, sekaigus dicompoundkan dengan
sweling melalui “crosslink” untuk menerima
komponen polimer sintetik, baik dengan insitu
compatibiliser maupun starch-grafted –polimer.
Reactive compatibiliser

www.enviplast.com | info@enviplast.com 12
Viskositas campuran Starch
• Extrusion adalah methoda prosesing komersil untuk
thermoplastik maupun bioplastik yang bersifat thermoplastik ,
baik sebagai film maupun sheet. Kadang cara lain seperti
injection molding, Press molding, blow molding juga
digunakan.. Extrusi material yang mengandung starch cukup
sulit. Oleh karena itu langkah pertama selalu dengan
menjadikanya thermoplastic starch . Meskipun demikian
dibutuhkan tekanan di die cukup besar , karena viskositas
gelatin yang cukup besar. Oleh karenanya dibutuhkan
extruder dengan rasio kompresi besar , namun flow ratenya
harus cukup tinggi dan gap di die yang rendah.
 Suhu process Blown
Film
• Terdiri atas extruder , anular die, sistem
pendingin tower penarik buble, printing
area, sistem penggulung , alat, oprasi
sealing dan pemotongan.
• Extruder umumnya Single Screw dengan
rasio
L/D 30 sampai 31,
Untul memproses Starch Based material
suhu yang digunakan tidak boleh tinggi,
namun harus masak sempurna, sehingga
perlu untuk memberikan tekanan kearah
Die dilengkapi dengan kneader didaerah
metering.
• Karena besarnya tekanan pada daerah
Die, maka Gear Reducer, harus mampu
menurunkan rpm motor ke rpm screw
hampir 10 x . Rpm motor sekitar 960 rpm,
RPM Screw 80 an
• Blow up ratio untuk material starch based
bisa mencapai 1:9.
 • Die umumnya Spiral Flow Die
• Melt masuk melalui adapter yang membelok
keatas, mengalir sepanjang channel spiral
mandrel, kadang juga meluap ke channel lain,
karena makin keatas kedalaman channel makin
landai
Komponen • Udara ditiupkan melalui pipa dibawah
mandrel. Tiupan udara membentuk buble ,
setelah diperoleh ukuran diameter buble yg
Die sesuai dan stabil, tekanan udara dijaga
kondisinya tetap.
• Saat mendingin , kembali ke tekanan normal,
akibat kehilangan moisture akan terjadi size
recovery ,dari keadaan swelling . Akibat
recovery dari swelling, ukuran silinder printing
harus di adjust ,mengikuti recovery ini.
Made from sustainable resources : Life Cycle of
very low carbon footprint ENVIPLAST®

From Nature Back to Nature

www.enviplast.com | info@enviplast.com 17
End of life standard: Conform to EN 13432 in
Biodegradation

www.enviplast.com | info@enviplast.com 18
Should Be Composted After Disposal

TAKAKURA
COMPOSTING
SYSTEM

0 day 50 days 53 days

57 days 60 days 64 days

www.enviplast.com | info@enviplast.com 19
 We are exploring the possible
application for flexible
Development packaging as a core layer
of
ENVIPLAST® Enviplast® has a very
Film as hydrophylic surface
Oxygen characteristic  dry lamination
Barrier in is a possible approach.
Flexible
Packaging
More economical alternative

www.enviplast.com | info@enviplast.com 20
 What is PLA?
• PLA – Poly Lactic Acid
• Made from Plants, not Petroleum
• Starch in the plant is converted by
fermentation to Lactic Acid, which is
polymerized to make PLA
• Can be made from plants containing
starches/sugars like corn, sugar beets, sugar
cane, wheat etc.
 Who Makes It?
• NatureWorks – biggest PLA producer in the
world
• Owned by Cargill
• Factory in Blair, NE – 300 million lbs/year
• Uses Corn Starch to make PLA
• Other PLA manufacturers in Europe and China.
How Much Corn goes to make PLA?
• 2.2 lbs of corn needed for 1 lb of PLA
– Byproducts can be used for producing germ oil,
corn gluten meal, etc
• US Corn Production – 700 billion lbs
• US PLA Production – 300 million lbs
• 0.09% of total US corn production
GMO vs non-
GMO
• 86% of Corn
Grown in USA
is GMO
• Corn used to
make PLA in
USA is corn
available 30
miles around
 End of Life Options -
Compostability
• Is fully Compostable in a Commercial
Composting Facility within 90 days
• Din Certco (Europe), BPI (USA), GreenPLA
(Japan) certifications
• Reduces Environmental Pollution
• Is not Home Compostable
• Is not Soil Degradable
• Is not Marine Degradable
• Does not degrade in a landfill
 End of Life Options - Feedstock
Recycling
• PLA can be recycled back to Lactic Acid, via a
chemical process called hydrolysis
• Once converted to Lactic Acid, it can be
remade into PLA
• Allows infinite recycling of feedstock vs.
normal down cycling of oil-based plastics
 Common Products
Common products containing PLA: food
packaging, disposable tableware, diapers

27
 Imperial College
Polylactide or Poly(lactic acid) - PLA (www.natureworksllc.com) London

The first mainstream polymer to be made from renewable resources.

PLA is: biodegradable, biocompatible and bioresorbable

enzymatic
degradation fermentation

corn starch lactic acid

step-growth (-H2O)
condensation
ring-opening
polymerisation
* heat

* *
(chain growth)
*

polylactic acid, PLA lactide oligomers

These 2 lectures focus on this step

4I-11 - 7 - 3
 Imperial College
Initiators London

Typical initiators for lactide polymerisation are metal-alkoxides, e.g. Al(OiPr)3:

Acyl-oxygen bond breaks

Industrially, the initiator used is a tin(II) carboxylate - in the presence of alcohol, this is
believed to form tin(II) alkoxides, and these are the actual initiating species:

tin(II) bis(2-ethylhexanoate) true initiator

"SnOct2"

4I-11 - 7 - 4
 Imperial College
PLA - physical properties depend on tacticity London

Polymer Tm (°C) Tg (°C) Modulus Degradation time

(GPa) (months)
isotactic PLA 170 60 2.7 >24

syndiotactic PLA 153 45 n/a n/a

heterotactic PLA amorphous 49 n/a n/a

atactic PLA amorphous 55 1.9 12 - 16

There is one other important form of PLA known as an isotactic stereocomplex:

isotactic
poly(L-lactide)
mix and
co-crystallise Tm > 235 °C
isotactic
poly(D-lactide)

4I-11 - 7 - 8
 Imperial College
Single-site catalysts London

X
Ln M

sterically bulky e.g. Cp2ZrMe+ for the

ancillary ligand(s) polymerisation of ethene

substrate approaches
vacant coordination site
and may then react with X

PLA stereochemistry potentially controlled by the sterics / chirality of Ln

4I-11 - 7 - 9
Multi Layer Flexible Packaging
Potential Application
Surface Layer ( e.g. OPP 10 microns )
Tie / Adhesive Layer ( 2 microns )

ENVIPLAST® ( 40 microns )

Tie / Adhesive Layer ( 2 microns )

Sealing Layer ( e.g. LLDPE 10 microns )

Approx. 60% biobased content

www.enviplast.com | info@enviplast.com 32
 33

• Method : Initial, Peeling angle T

Peel Strength • Cross head speed 300 mm/min
Test of • Adhesive : Polyester -polyurethane
• Results :
Hand • PET/adhesive/Enviplast® : 1.2 N/15 mm
Laminated •
•
Nylon/adhesive/Enviplast® : 1.3 N/15 mm
PET/adhesive/Nylon 6 : 4.8 N/15 mm
Film

www.enviplast.com | info@enviplast.com
 Structure : OPP 20/adhesive/Enviplast®
40/adhesive/LLDPE 40

Adhesive : Polyester polyurethane, coating weight :

3.5 g/m2

Speed : 100 m/min

Trial in a Chamber temperature : 50 - 60 °C

Lamination
Peel strength test result :
Machine • Peel angle :T
• Cross head speed : 300 m/min
• OPP/Enviplast® : 2.1 N/15 mm
• Enviplast®/LLDPE : 2.3 N/15 mm

Result of O2TR : 1.78 cc/m2.day (ASTM D3985, 23°C,

0%RH)

Result of MVTR : 2.879 g/m2.day (ASTM F1249, 23°C,

90%RH)
www.enviplast.com | info@enviplast.com 34
Thank You for Saving My Life and Our
World

www.enviplast.com | info@enviplast.com