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ARS_PRESENTATION on BIO FILLERS 22072024.pptx
- 1. Presentation on Development of PBAT based Bio Filler Masterbatch By Suresh Anandarao
- 2. CONTENTS Introduction Products & Applications Cost Analysis Challenges and Troubleshooting Time lines and Budget Manufacturing process of Bio-filler masterbatch Objectives Market scenario Conclusion
- 3. Bio filler masterbatch the mix between bioplastic and filler masterbatch? Bio filler masterbatch is the mixture of bio resin, specific fillers (calcium carbonate powder, talc powder, barium powder,) and additives in different formulas to completely fulfill end-products requirements. The introduction of bio resin allows end-products to be biodegradable after use, thus minimizing the harmful effects on the environment. PBAT based fillers can be processed by conventional film techniques yielding films with mechanical properties similar to that of LDPE. As such, PBAT incorporation can help to improve the toughness of polymer blends that contain brittle polymers such as PLA (Poly lactic acid) or TPA( thermoplastic starch) without affecting biodegradable characteristics Introduction
- 4. Market scenario Global demand for PBAT (polybutylene adipate terephthalate ) is on the rise due to demand for SUP (single use plastics) in Packaging is increasing in terms of shopping bags, packaging solutions, agricultural films, cutlery & other consumer items . Due to flexibility and high elongation at break , PBAT & its composites are widely used to develop bio- degradable blown films , this is evident since shopping bags & other packaging solutions are anticipated to dominate the highest revenue share among all types in the market. PBAT based bio filler market is expected to grow @ 8.7% CAGR ( 2021-2031) as many companies are exploring composites based on CaCO3 (less expensive) with PBAT (Cost competitive vis--vis other biodegradable plastics). Globally many packaging solutions providers are exploring PBAT based stand up pouches for food
- 5. Cost reduction Bio filler masterbatch reduces the amount of bioplastic consumed, which is relatively high-expense. CaCO3 is a good thermal conductive, it considerably shortens the product cycle and minimizes the energy consumption, which facilitates the production efficiency. Properties enhancement Adding bio filler, end-products are provided with great stiffness, flexural durability, less shrinkage, good thermal conductivity, whiteness and transparency. Use of bio filler masterbatch comes at the cost of mechanical degradation is a misconception. Processing aid additive Streamline the blown film process. Bio filler masterbatch reduces the blocking between them, thus improving the effectiveness of the production. How does bio filler masterbatch benefit end-products?
- 6. Improve the dimensional stability of plastic products The addition of CaCo3 powder plays a skeleton role in plastic products and has great significant on the dimensional stability of plastic products. Improve the processing properties of plastics The addition of CaCo3 powder can change the rheological properties of plastic. Calcium carbonate powder is usually added in larger quantities to facilitate their mixing with other components and the processing and moulding of plastics. Improve the heat resistance of plastic products Improve the astigmatism of plastics Calcium carbonate powder with a whiteness above 90 has obvious whitening effect in plastic products. It can make the product have some special properties The addition of calcium carbonate powder can improve the electroplating and printing properties of some products. Other Benefits of PBAT based filler masterbatch
- 7. 1. Bio filler masterbatch containing calcium carbonate powder (CaCO3) CaCO3 bio filler is widely used in several industries, such as blown film, extrusion, injection molding. And due to its great biodegradability, it is specifically preferable in manufacturing single-use products. 2. Bio filler masterbatch containing talc powder A good thermal resistance, good stiffness and low shrinkage and is widely used in a wide variety of fields ranging from blown film to extrusion, thermoforming, and injection molding. 3. Bio filler masterbatch containing barium sulfate Specifically preferred in the retail industry (shopping bags, roll bag), F&B (food packaging films) and agriculture (mulching film, greenhouse films). ommon types of bio filler masterbatches and their uses
- 8. 1. Development of PBAT based bio filler masterbatch for to reduce cost and to achieve desirable properties in the end product. 2. Development of masterbatches varying the composition for different applications and composition optimization. 3. In-depth analysis of the effect of developed bio filler masterbatch on mechanical property, thermal property, surface texture, barrier property and other functional properties of the end product. 4. Evaluation of the effect of developed bio filler masterbatch on biodegradability and/or compostability of the end product. 5. Establish a feasible industrial production process. 6. Yielding ROI within the expected timelines OBJECTIVES
- 9. Typical compositions of Bio-filler Masterbatch End Application PBAT: 20% - 30% Calcium Carbonate (CaCO3)/Talk: 70% - 80% Packaging Films PBAT: 20% - 25% Calcium Carbonate (CaCO3): 60% - 75% UV Stabilizers: 5% - 15% Agricultural Films PLA: 10% - 30% Talc: 45% - 80% Impact Modifier: 5% - 15% Processing Aid: 5% - 10% Injection-Molded Products PLA: 10% - 20% Wood Flour: 65% - 85% Starch-based Binder: 5% - 15% Disposable Cutlery PLA/PBAT: 10% - 20% Rice Husk Ash (RHA): 60% - 80% Plant Nutrients: 10% - 20% Horticultural Pots PBAT: 20% - 30% PRODUCTS & APPLICATIONS
- 10. Surface treatment or particle size reduction of the filler (if required). High speed mixing of the filler and carrier resin in presence of other additives The mixture is processed into liquid or to a dough-like state at high temperature The blend is cooled and processed through a twin screw extruder Cut into beads to a particular size. Premix process Twin screw extrusion BIO-FILLER MASTERBATCH PRODUCTION PROCESS
- 11. Challenges Issue Troubleshooting AGGLOMERATION OF THE FILLER Large number of white spots are bound to form on the film. Even white hard particles may form a "cloud. Prevent excessive friction during surface treatment to avoid static electricity generation by friction. PROPORTION OF THE FILLER IN THE MASTERBATCH Imbalance of cost of production and the desired property. The weight percentage of the filler should not more than 80%. R&D to optimize the composition. PHYSICAL MIXING In the twin-screw extruder, the filler particle separate. Uneven material mixing results "cloud" or white spots on the final product. Mixing time and temperature should be optimum. CHOICE OF EXTRUDER Improper mixing. Product with poor surface texture. Co-rotating twin-screw extruders are superior to single-screw extruders. Water cooling of the masterbatch is Air-cooled die face hot cutting process should be preferred. CHALLENGES IN BIO FILLER MASTERBATCH PRODUCTION
- 12. Challenges Issue Troubleshooting BREAKING STRENGTH The Melt Flowing Index of filler masterbatch is extremely lower than the resin. filler does not melt properly when processed results in breaking the film. Loading of sufficient carrier resin in the filler masterbatch BLACK DOT IN FILM High moisture content in the filler masterbatch and resin. Proper preheating of the components before processing. FILM PUNCTURE Large particle size of the filler. Improper mixing. Particle size reduction and surface treatment of the filler HIGH-SPEED TAPE BREAKING High speed extrusion. Different flow rate of the components. Process optimization FILM SURFACE IS BLOOMING Unsuitable filler masterbatch. Selection of suitable masterbatch for different polymer compositions. BASIC CHALLENGES IN BLOWN FILM PRODUCTION WITH BIO MASTERBATCH
- 13. Types of Bio-filler masterbatch Raw material cost (RMC) (in INR per kg) Manufacturing and operation cost (in INR per kg) Total cost (in INR per kg) Market selling price (in INR per kg) PBAT-CaCO3 (80%) 62-82 15-25 77-107 120-150 PBAT-Talk (80%) 58-78 15-20 73-98 120-140 PBAT-Barium sulphate (80%) 74-94 15-25 89-119 140-180 PBAT-Rice husk ash Based on the availability 15-30 - 90-120 PBAT-Wood flour/ other natural filler Based on the availability 15-30 - 90-120 NOTE The manufacturing cost highly depends on the market dynamics, price of PBAT, and the percentage of filler loading. The bulk manufacturing will reduce the cost of production. The RMC will be in the higher side for the bio-filler masterbatch for special applications (like Impact modified bio-filler masterbatch). COST ANALYSIS OF BIO FILLER MASTERBATCH
- 14. Deliverable and Milestone Timeline (in months) 0-2 3-4 5-6 7-8 9-10 Project review & initial arrangements Work plan and experiment design Procurement of polymers and other required consumables Composition optimization Experimental trials Property analysis and optimization Technology transfer PROJECT TIMELINE
- 15. Sl. No. Item description Amount (in INR) 1 -a) b) Machinery & anclliary equipments Raw material (for 100T capacity p.m) 55,00,000 25,00,000 2-a) b) Manpower (Production,QC&RnD, Marketing) Project cost 1,20,000 4,50,000 3-a) b) Characterization and Analysis (RnD) & Testing charges CPCB approval 6,00,000 4,00,000 4 Contingency fund 1,00,000 5 Sub Total 96,70,000 6 Miscellaneous expenses & Over head cost (10%) 9,67,000 Total*(Approx) 10,63,70,000 PROPOSED BUDGET FOR SETTING UP THIS BIO FILLER MANUFACTURING PROJECT
- 16. www.arsconsultant.top CONCLUSION As environmental concerns grow, more and more companies are looking for eco-friendly and sustainable alternatives to traditional plastics. In this pursuit, PBAT has emerged as a promising option. For those looking to incorporate PBAT plastic into their products, finding a reliable supplier is crucial. PBAT and PLA are both biodegradable and compostable plastics that are gaining popularity as alternatives to traditional petroleum-based plastics. However, they have some key differences that set them apart from each other. - Performance: PBAT is flexible and tough, making it suitable for a wide range of applications such as food packaging and biodegradable shopping bags. On the other hand, PLA is rigid and brittle, making it more suitable for applications where stiffness and dimensional stability are important, such as cutlery, drinking straws, and packaging for electronics. - Biodegradability and compostability: Both PBAT and PLA are biodegradable and compostable, but PBAT has a faster degradation rate compared to PLA, meaning it will break down more quickly in the environment. - Cost: PBAT is more expensive to produce compared to traditional petroleum-based plastics, while PLA is typically more expensive compared to PBAT. - Limited industrial use: PBAT is not as widely used in the industry compared to traditional plastics, which may limit its availability and make it harder to find a suitable solution for some applications. - Environmental impact: Although PBAT is biodegradable and compostable, it still has an impact on the environment if not disposed of properly. The composting process also requires specific conditions to break down the material effectively. - Performance limitations: PBAT has some performance limitations compared to traditional petroleum-based plastics, such as a lower melting temperature and reduced resistance to UV light and heat.
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