These thermoformed containers with heat-sealable lids are made from BASF's partially bio-based Ecovio and are particularly suitable for vegetarian and vegan foods and dairy products.

Contributed by Lily Manolis Sherman

We recently learned about a cooperation project between the German manufacturer of blown and cast film Suedpack and the global thermoforming and tooling system manufacturer Illig Maschinenbau, which proved that under current market conditions, it has a certified compostable and mainly biological Thermoformed food packaging based on components is possible.

Partners stated that this development is in line with the growing trend and demand for compostable and bio-based packaging solutions in more and more countries. In particular, food packaging with organic residues is difficult to handle in the traditional mechanical recycling process. This makes industrial compostable containers a viable alternative, where proper composting infrastructure exists. In this way, food waste, including packaging, can be recycled organically instead of heat.

The new trays with heat-seal lids can be used for packaging vegetarian and vegan foods, as well as dairy products such as yogurt or cheese. It is mainly made of BASF's certified compostable (DIN EN 13432) part of the bio-based plastic Ecovio (BASF's Ecoflex biodegradable aliphatic copolyester and 45% PLA), dyed green for this application.

Suedpack uses an extrusion process to produce film and has developed a laminated cover film, which can also be used for industrial composting. Illig designed the thermoforming tool to thermoform the tray with film and seal the lid. The result is a thin-walled food container that replicates the shape of the mold in detail and can be produced at the same speed as similar packaging made of traditional plastic.

The ecovio bioplastic used in this case study has been specifically optimized for film extrusion and subsequent thermoforming. It can be processed on a standard single extruder or co-extruder into a film with or without an additional oxygen barrier. This bioplastic has a high heat distortion temperature of 95 C/203 F, is approved for contact with food, and has mechanical properties similar to PP.

The flexible film developed by Suedpack for the lid consists of a multilayer, partially transparent laminate based on PLA and brown paper. According to DIN EN 13432, all components can be composted industrially. The film can be heat-sealed with other PLA-based materials, and can optionally be equipped with a barrier layer.

Dr. Jürgen Betz, who is responsible for the research and development of extrusion at Suedpack, said: “Together with Illig, the world’s leading manufacturer of thermoforming and moulding systems, we were able to prove that films made of Ecovio materials can be effectively produced not only on ordinary extrusion lines, but also on thermal It also showed excellent performance during processing on the molding production line,"

According to Sven Engelmann, Head of Technology Center and Packaging Development at Illig, Heilbronn, this joint project approach allowed them to demonstrate how certified compostable and bio-based plastics can be easily thermoformed and further processed on standard machines. "We are able to run at the same machine speed as polypropylene. In particular, our thermoforming tool reproduces the words "Vegetarian Burger" embedded in the bottom of the tray in great detail. This opens up many design possibilities for thermoformed industrial compostable packaging sex."

Twin screw extrusion is the preferred method for compounding PLA and other biopolymers. But processing PLA is complicated because it is sensitive to heat and shear. If there is moisture in molten PLA, it is also prone to hydrolytic degradation. The following are the test results of a machine manufacturer.

Extruded decorative panels are still driving the emerging wood-filled plastic market. However, the wood composite materials of injection molding and compression molding are becoming more and more powerful, and the extruded profiles are developing toward more complex shapes of wood products.

The mixing and extruding of wood fibers in a plastic matrix is ​​technically demanding. It requires careful attention to formula, drying and extrusion temperature

© 2021 Gardner Business Media, Inc. Privacy Policy [Login]