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Bio fillers eco friendly products technical & business presentationpptx
- 1. A Scientific Research Proposal on Development of PBAT based Bio Filler Masterbatch
- 2. CONTENT Introduction End Applications Cost Analysis Challenges and Troubleshooting Timeline and Budget Manufacturing process of Bio-filler masterbatch Objectives
- 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.
- 4. How does bio filler masterbatch benefit end- products? 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.
- 5. 1. 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. 2. 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. 3. Improve the heat resistance of plastic products 4. Improve the astigmatism of plastics Calcium carbonate powder with a whiteness above 90 has obvious whitening effect in plastic products. 5. 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
- 6. 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 Common types of bio filler masterbatches and their uses
- 7. OBJECTIVES 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.
- 8. 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% Talc: 55% - 75% Softening Agent: 5% - 15% Non-Woven Fabrics
- 9. 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. Bio-filler Masterbatch Production Premix process Twin screw extrusion
- 10. Challenges in Bio-filler Masterbatch Production 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. COOLING METHOD Water cooling of the masterbatch is a major hidden danger to the blown film. Air-cooled die face hot cutting process should be preferred. When the extruder has a large diameter and the output is higher than 300kg/h, it is preferable to use a belt cooling method.
- 11. 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. BLOCKING THE NET Masterbatch surface texture. Selection of good quality filler Basic challenges in Film production process with Bio-filler Masterbatch
- 12. Cost analysis of the bio-filler masterbatch 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 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).
- 13. Deliverable and Milestone Timeline (in months) 0-2 3-4 5-6 7-8 9-10 Literature review Work plan and experiment design Procurement of polymers and other required consumables Composition optimization Experimental trials Property analysis and optimization Technology transfer PROJECT TIMELINE
- 14. Sl. No. Item description Amount (in INR) 1 Chemicals and Consumables 1,00,000.00 2 Manpower 1- Senior Research Fellow (SRF) (42,000+18% HRA per month) 1- Project Assistant (20,000+18% HRA per month) 7,31,600.00 3 Characterization and Analysis 4,00,000.00 4 Contingency 50,000.00 5 Sub Total 12,81,600.00 6 Over head cost (15%) 1,92,240.00 Total 14,73,840.00 Proposed Budget