An industrially compostable biopolymer for blow film and the process for preparing the same

Abstract

The present invention relates to an industrially compostable biopolymer for blow film and the process for preparing the same. Moreover, the present invention provides an industrially compostable biopolymer for blow film wherein the biopolymer for blow film comprises of compostable resin, natural fillers, compatibilizer, and lubricant. The present invention is to provide an industrially compostable biopolymer for blow film that easily disintegrates in nature.

Description

[0001] AN INDUSTRIALLY COMPOSTABLE BIOPOLYMER FOR BLOW FILM AND THE PROCESS FOR PREPARING THE SAME

[0002] FIELD OF THE INVENTION

[0003] This invention pertains to a biodegradable polymer designed for industrial composting. More particularly, the present invention relates to an industrial compostable biodegradable polymer for blow film that degrades easily in the industrial composting facility. The present invention also encompasses both the biodegradable polymer blow film and the method for its preparation.

[0004] BACKGROUND OF THE INVENTION

[0005] With the rapid development of plastic’s industry technology, the increasing number of plastic products has brought about a near-destructive disaster to the environment; a large amount of plastic waste has been abandoned in the social environment, and the “white pollution” produced has become the most difficult problem in the current countries. To fundamentally solve the environmental pollution problem of waste plastics, plastic products that can degrade and easily degrade should be used instead of the existing plastic products.

[0006] Plastics are synthetic compounds of polymers, which are lengthy molecules made up of carbon atom chains. A polymer consists of numerous repeating units known as monomers. The chain structures are interspersed with atoms such as hydrogen, nitrogen, oxygen and sulphur. It is generally a synthetic or semi-synthetic material typically derived from petrochemicals or substances such as cellulose or starch.

[0007] Plastic pollution is one of the causes that represents a significant global crisis today. It is a major contributor to biodiversity loss and ecosystem degradation, posing threats to human health, impacting water safety, straining economic activities, and worsening climate change. Thus, as conventional single use plastics are causing heavy pollution of environment, there is a need to develop plastics that are degradable and compostable in nature. Biodegradable plastic made from renewable resources decreases the dependence on petroleum and reduces the amount of waste material, while still yielding a product that provides similar benefits to traditional plastics. The major difference between synthetic polymers and natural polymers is the presence of oxygen and nitrogen in the natural polymers. The oxygen and nitrogen in the polymer structure permit the polymer to biodegrade.

[0008] Starch-based biodegradable plastic is one of the most promising degradable plastics at present and is generally prepared by blending starch, plasticizer, and degradable resin, having better processing performance and cost advantage compared with pure degradable resin. The blending of starch with plastics improves water resistance, processing properties, and mechanical properties.

[0009] Biodegradable polymers are being developed as an alternative to non- biodegradable plastics across various applications. The most effective way to manage non-biodegradable plastic waste is to replace costly, non-recyclable materials with environmentally friendly biodegradable polymers, which offer a more sustainable solution through recycling and reuse. Biodegradable polymers are materials designed to break down more quickly than conventional plastics. They can be derived from natural sources, such as corn starch (polylactic acid, PLA), or engineered to degrade more rapidly under specific conditions.

[0010] However, there are so many problems in biodegradable polymers in real life testing. They tend to face environmental factors so that they can degrade or their properties reduces with respect to time but non degradable polymers can overcome this problem but they are not environment friendly. To overcome this both the problems there is a need of stable material which can be degraded in industrial composting facility so that it has better environmental resistance with degradability. Thus, the inventors of the present invention have prepared an industrially compostable biopolymer that overcome the aforementioned problems, as they degrade in industrial composting facilities while offering improved environmental resistance and degradability.

[0011] OBJECTIVE OF THE INVENTION

[0012] The main objective of the present invention is to provide an industrially compostable biopolymer for blow film.

[0013] Yet another objective of the present invention is to provide an industrially compostable biopolymer for blow film that is compatible with both single-screw and twin-screw extruders.

[0014] Another objective of the present invention is to provide an industrially compostable biopolymer for blow film that degrades in industrial composting facility.

[0015] Another objective of the present invention is to provide an industrially compostable biopolymer for blow film that disintegrates completely in industrial compostable equipment’s.

[0016] Another objective of the present invention is to provide an industrially compostable biopolymer for blow film that has a smooth texture indistinguishable from conventionally available plastic and available degradable alternatives.

[0017] Another objective of the present invention is to provide an industrially compostable biopolymer for blow film having higher strength and quality compared to other available degradable alternatives. Another objective of the present invention is to provide an industrially compostable blow biopolymer for film that is commercially viable and financially beneficial due to lower capital costs and power consumption.

[0018] SUMMARY OF THE INVENTION

[0019] The main aspect of the present invention is to provide an industrially compostable biopolymer for blow film.

[0020] Another main aspect of the present invention is to provide an industrially compostable biopolymer for blow film wherein the blow film comprises compostable resin, natural filler, lubricant and compatibilizer.

[0021] Another aspect of the present invention is to provide an industrially compostable biopolymer for blow film that easily disintegrates in industrially compostable facilities.

[0022] The other aspect of the present invention is to provide an industrially compostable biopolymer for blow film and the process for preparing the same.

[0023] Another aspect of the present invention is to provide an industrially compostable biopolymer having good environmental resistance in environment so that it has long working life like plastic but it degrades in industrial composting facility.

[0024] DESCRIPTION OF THE INVENTION

[0025] The main embodiment of the present invention is to provide an industrially compostable biopolymer for blow film.

[0026] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are now described.

[0027] As used herein, whether in a transitional phase or in the body of a claim, the terms “comprise(s)” and “comprising” are to be interpreted as having an open-ended meaning. That is, the terms are to be interpreted synonymously with the phrases “having at least” or “including at least”. When used in the context of a process, the term “comprising” means that the process includes at least the recited steps, but may include additional steps. When used in the context of a composition, the term “comprising” means that the composition includes at least the recited features or components, but may also include additional features or components.

[0028] As used herein, the singular forms “a,” “an” and “the” specifically also encompass the plural forms of the terms to which they refer, unless the content clearly dictates otherwise.

[0029] The following terms shall have, for the purposes of this application, the respective meanings set forth below.

[0030] "Optional" or "optionally' means that the subsequently described event or circumstance may or may not occur and that the description includes instances where the event occurs and instances where it does not.

[0031] The term “about” is used herein to mean approximately, in the region of, roughly, or around. When the term “about” is used in conjunction with a numerical range, it modifies that range by extending the boundaries above and below the numerical values set forth. In general, the term “about” or “approximately” is used herein to modify a numerical value above and below the stated value by a variance of 20%.

[0032] The present invention overcomes the aforesaid drawbacks of the above, and other objects, features, and advantages of the present invention will now be described in greater detail. Also, the following description includes various specific details and is to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that: without departing from the scope and spirit of the present disclosure and its various embodiments there may be any number of changes and modifications described herein.

[0033] As will be understood by one skilled in the art, for any and all purposes, such as in terms of providing a written description, all ranges disclosed herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, et cetera As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc As will also be understood by one skilled in the art all language such as “up to,” “at least,” and the like include the number recited and refer to ranges which can be subsequently broken down into sub-ranges as discussed above.

[0034] Nothing in this disclosure is to be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention. As used in this document, the term "comprising" means "including, but not limited to.

[0035] The term “blow film” used herein, is defined as a long continuous film made by extrusion process primarily used for packaging.

[0036] As used herein in the present invention, the terms 'biodegradable polymer,' 'granules,' and 'pellets' can be used interchangeably.

[0037] The main embodiment of the present invention is to an industrially compostable biopolymer for blow film, wherein the biopolymer for blow film comprises compostable resin, natural filler, lubricant and compatibilizer. As per another main embodiment of the present invention, the said compostable resin is selected from but not limited to polybutylene adipate terephthalate, polyhydroxybutyrate, polylactic acid, polyhydroxyalkalonates, polybutylene succinate, and polycaprolactone.

[0038] As per a preferred embodiment, the compostable resin is polybutylene adipate terephthalate or polylactic acid.

[0039] As per another embodiment of the present invention, the compostable resin used is in the range of 1-100 parts, more preferably 10-90 parts and most preferably in 20-80 parts.

[0040] As per another embodiment of the present invention, wherein said natural fillers are selected from but not limited to calcium carbonate, titanium dioxide, kaolin, mica and talc.

[0041] As per a preferred embodiment, the said natural filler is calcium carbonate.

[0042] As per another embodiment of the present invention, wherein said natural filler is in the range of 1-100 parts, more preferably 10-90 parts and most preferably in 20-80 parts.

[0043] As per another embodiment of the present invention, wherein said lubricants are selected from stearic acid, wax, white oil and vegetable oils.

[0044] As per a preferred embodiment, the lubricant is stearic acid.

[0045] As per another embodiment of the present invention, wherein said lubricant is in the range of 0.1 to 10 parts, more preferably 0.5 to 7 parts and most preferably 1 to 5 parts. As per another embodiment of the present invention, wherein said compatibilizer is selected from but not limited to Epoxidized soybean oil, stearic acid, titanate, at least one of aluminate, silane coupling agent KH550, silane coupling agent KH560, silane coupling agent KH570.

[0046] As per a preferred embodiment, said compatibilizer is Epoxidized soybean oil.

[0047] As per another embodiment of the present invention, the said compatibilizer used is in the range of 0.01 to 20 parts, more preferably 0.1 to 15 parts and most preferably 0.5 to 10 parts.

[0048] As per another embodiment of the present invention, the process of preparing the industrially compostable biopolymer for blow film comprises following steps: a. Mixing compostable resin, natural filler, compatibilizer and lubricant in high speed mixer at 700-800 rpm and heat upto 75 to 85° C to obtain a homogenous mixture; b. Transferring the homogenous mixture of step (a) into a single screw extruder at a feed rate of 500 grams / hour; c. Transferring the mixture of step (b) into a single or twin-screw compounding machine and pelletizing it at 160 to 185° C to obtain a granule of compostable biopolymer; d. Colling and drying the granules of step (c) with conventional extrusion machine.

[0049] Yet according to another embodiment of the present invention, the industrially compostable biopolymer for blow film comprises of 1 to 100 parts compostable resins, 1 to 100 parts natural filler, 0.1 to 10 parts lubricants, and 0.01 to 20 parts of compatibilizer. Yet according to another embodiment of the present invention, the industrially compostable biopolymer for blow film comprises of 10 to 90 parts compostable resins, 10 to 90 parts natural filler, 0.5 to 7 parts lubricants, and 0.1 to 15 parts of compatibilizer.

[0050] Yet according to another embodiment of the present invention, the industrially compostable biopolymer for blow film comprises of 20 to 80 parts compostable resins, 20 to 80 parts natural filler, 1 to 5 parts lubricants, and 0.5 to 10 parts of compatibilizer.

[0051] As per one another embodiment of the present invention, said biopolymer for blow film has industrial composability so it exhibits long life as plastic but environment friendly as bridgeable in composting facility.

[0052] Another embodiment of the present invention, the industrially compostable biopolymer for blow film are used in the preparation of products including but not limited to carry bags, garbage liners, packaging bags, shrink wrap films, stretch film, bag film, and seal packaging film.

[0053] Another embodiment of the present invention, the industrially compostable biopolymer for blow film prepared has a smooth surface, higher strength, high quality, commercially viable, and financially beneficial due to lower capital costs and power consumption.

[0054] The invention is further illustrated by the following examples which are provided to be exemplary of the invention and do not limit the scope of the invention. While the present invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the present invention. EXAMPLES

[0055] EXAMPLE 1: COMPOSITION OF AN INDUSTRIALLY COMPOSTABLE

[0056] BIOPOLYMER FOR BLOW FILM

[0057] Table 1: Composition of industrially compostable biopolymer for blow film

[0058] EXAMPLE 2: TRIAL BATCHES TO PREPARE AN INDUSTRIALLY COMPOSTABLE BIOPOLYMER FOR BLOW FILM The below table are the trial batches for the trial batches for the industrially compostable biopolymer for blow film.

[0059] Table 2: Trial batches of preparing industrially compostable biopolymer for blow films

[0060] The process for preparation of an industrially compostable biopolymer for blow film comprises following step: a. Mixed 40 parts of PBAT / PLA, 40 parts of calcium carbonate, 0.5 parts of Epoxidized soybean oil and 3 parts of stearic acid in high speed mixer at 700-800 rpm and heat upto 75 to 85° C to obtain a homogenous mixture; b. Transferred the homogenous mixture of step (a) into a single screw extruder at a feed rate of 500 grams / hour; c. Transferred the mixture of step (b) into a single or twin-screw compounding machine and pelletizing it at 160 to 185° C to obtain a granule of compostable biopolymer; d. Cooled and dried the granules of step (c) with conventional extrusion machine.

[0061] EXAMPLE 3: EVALUATION PARAMETRES FOR TRIAL BATCHES OF AN INDUSTRIALLY COMPOSTABLE BIOPOLYMER FOR BLOW FILM

[0062] Table 3: Evaluation of trial batches of industrially compostable biopolymer for blow film

[0063] All samples are placed in 55-degree Celsius aerobic incubator for 180 days as per ISO- 17088, and more than 90% weight loss was achieved and also when placed in soil at room temperature for 180 days 15% weight loss was achieved.

[0064] EXAMPLE 4: OPTIMIZED BATCH OF AN INDUSTRIALLY

[0065] COMPOSTABLE BIOPOLYMER FOR BLOW FILM

[0066] Table 4: Optimized batch of industrially compostable biopolymer for blow film

[0067] EXAMPLE 5: COMPARATIVE ANALYSIS OF THE INDUSTRIALLY COMPOSTABLE BIOPOLYMER FOR BLOW FILM WITH MARKETED POLYMER

[0068] A comparative analysis was carried for industrially compostable biopolymer for blow film with the marketed formulation, where the marketed formulation comprises of 70 parts polybutylene adipate terephthalate, 10 parts polylactic acid, 10 parts starch and 10 parts nucleating agent.

[0069] Due to high resin contents in the marketed formulation the cost of manufacturing will be higher. Further, the resins used in the marketed formulation are not compatible with each other so they cannot be mixed together. Due to this reason they are only compatible with twin screw extruders and using a compatibilizer to these marketed formulations increase the cost of the same. Thus, the industrially compostable biopolymer for blow film of the present invention overcomes the said drawbacks and make it more user friendly, cost benefiting and compostable / degradable in nature.

Claims

CLAIMSWe Claim:

1. An industrially compostable biopolymer for blow film, wherein said blow film comprises of compostable resin, natural filler, lubricant and compatibilizer.

2. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein compostable resin is selected from but not limited to polybutylene adipate terephthalate, polyhydroxybutyrate, polylactic acid, polyhydroxyalkalonates, polybutylene succinate, and polycaprolactone.

3. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein said compostable resin used is in the range of 1 to 100 parts, more preferably 10 to 90 parts and most preferably in 20 to 80 parts.

4. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein said natural fillers are selected from but not limited to calcium carbonate, titanium dioxide, kaolin, mica and talc.

5. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein said natural filler used is in the range of 1 to 100 parts, more preferably 10 to 90 parts and most preferably in 20 to 80 parts.

6. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein said lubricants are selected from stearic acid, wax, white oil and vegetable oils.

7. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein said lubricant used is in the range of 0.1 to 10 parts, more preferably 0.5 to 7 parts and most preferably 1 to 5 parts.

8. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein said compatibilizer is selected from but not limited to stearic acid, titanate, at least one of aluminate, silane coupling agent KH550, silane coupling agent KH560, silane coupling agent KH570.

9. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein said compatibilizer used is in the range of 0.01 to 20 parts, more preferably 0.1 to 15 parts and most preferably 0.5 to 10 parts.

10. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein the process of preparing the industrially compostable biopolymer for blow film comprises the following steps: a. Mixing compostable resin, natural filler, compatibilizer and lubricant in high speed mixer at 700-800 rpm and heat upto 75 to 85° C to obtain a homogenous mixture; b. Transferring the homogenous mixture of step (a) into a single screw extruder at a feed rate of 500 grams / hour; c. Transferring the mixture of step (b) into a single or twin-screw compounding machine and pelletizing it at 160 to 185° C to obtain a granule of compostable biopolymer; d. Colling and drying the granules of step (c) with conventional extrusion machine.

11. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein the biopolymer for blow film comprises of 1 to 100 parts compostable resins, 1 to 100 parts natural filler, 0.1 to 10 parts lubricants, and 0.01 to 20 parts of compatibilizer.

12. The industrially compostable biopolymer for blow film as claimed in claim 1, wherein said biopolymer for blow film has industrial composability so it exhibits long life as plastic but environment friendly as bridgeable in composting facility.

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