A PROCESS FOR PREPARING BIODEGRADABLE FILM FOR PACKAGING

Abstract

ABSTRACT A PROCESS FOR PREPARING BIODEGRADABLE FILM FOR PACKAGING The present invention relates to a novel process(100) for preparing biodegradable films designed for flexible packaging applications. The process(100) utilizes a combination of botanical components and polymers to produce films that are both durable and capable of rapid biodegradation under natural conditions. The process(100) involves milling botanical components(101) in a dry milling machine (102), followed by mixing(103) in an agitator mixer to form a homogeneous blend. The mixture is plasticized by adding a polymer combination(104) and stabilized(105) to ensure thermal stability and cross-linking. The mixture is melted(106) in a melting unit and extruded through a sheet die to form biodegradable films. The resulting films exhibit high tensile strength (32.45-57.63N/m²) and impact strength (53-64J/cm), with complete biodegradation achieved within 90-250 days under composting conditions. The process(100) addresses the challenges of existing biodegradable films by enhancing performance and decomposition rates, utilizing renewable resources, and reducing environmental pollution caused by conventional petroleum-based films.

Specification

Description:A PROCESS FOR PREPARING BIODEGRADABLE FILM FOR PACKAGING
FIELD OF THE INVENTION
[0001] The present invention in general relates to packaging applications using renewable botanical components and advanced formulation techniques. More particularly, the present invention relates to a process for preparing biodegradable film for packaging.
BACKGROUND
[0002] Petroleum-based plastic films are commonly used in packaging due to their durability and flexibility. However, these plastics are environmentally damaging because they take hundreds of years to decompose in landfills. Biodegradable films have been introduced as an alternative, but they often suffer from slow decomposition rates, dependence on non-renewable resources, and insufficient performance characteristics for practical use in packaging.
[0003] In recent years, there has been a growing demand for advanced packaging materials that address these issues by incorporating biodegradable materials. Several prior art processes have sought to address the challenges of biodegradable films but fall short in key areas compared to the present invention.
[0004] For instance, WO2020216803A1, which uses starch-based polymers, results in films with poor mechanical properties and limited biodegradability, particularly in non-industrial environments. Patent US4863655A proposes a method for biodegradable packaging but is heavily reliant on non-renewable, petroleum-based materials, making it less sustainable.
[0005] Similarly, US9469838B2 utilizes agricultural waste to create biofilms, yet it struggles to achieve the tensile and impact strength necessary for practical use in flexible packaging applications. Thus, the current invention not only surpasses these limitations but also delivers a more sustainable and high-performance solution.
[0006] The present invention addresses this need by providing a process for preparing biodegradable film for packaging that prepares a sustainable solution for packaging. The present invention provides a process for preparing biodegradable films using a combination of botanical components and polymers, resulting in improved biodegradability, mechanical strength, and environmental sustainability. In the current invention, the disclosed process enhances both strength and natural biodegradability of the film.
OBJECTS OF THE INVENTION
[0007] The object of the present invention is to provide a novel and efficient process for preparing biodegradable films for packaging, which significantly reduces environmental impact by utilizing sustainable and renewable botanical components.
[0008] It is another object of the present invention to improve the biodegradation rate of packaging films by employing a combination of botanical components and polymers that allows the films to decompose naturally in both composting environments and non-industrial settings, achieving full degradability within 90 to 250 days.
[0009] It is a further object of the present invention to enhance the mechanical performance of biodegradable films, ensuring they possess high tensile strength, impact strength, and flexibility, making them suitable for various packaging applications without compromising their biodegradability.
[0010] Another object of the invention is to utilize easily available botanical components such as coconut husk, rice husk, bamboo fiber, Chondrus extract, and agar, thus reducing the dependency on petroleum-based inputs and fostering resource efficiency in the production process.
[0011] Yet another object of the invention aims to achieve thermal stability and improved cross-linking between the botanical components and polymers by incorporating an optimized stabilizer combination, which ensures the films maintain structural integrity and performance during processing and use.
[0012] Another object of the invention is to reduce reliance on fossil fuels by promoting the use of renewable resources, thereby enhancing the sustainability and environmental compatibility of packaging materials.
[0013] Another object of the present invention is to optimize the production process by controlling parameters such as temperature, pressure, and melt flow rate during milling, mixing, and melting, to ensure consistent film formation with desirable physical properties.
[0014] The invention also seeks to provide biodegradable films that are versatile enough for use in various packaging scenarios, offering both durability and the ability to degrade fully after disposal, contributing to a circular economy.
SUMMARY OF THE INVENTION
[0015] In an aspect, the present invention discloses a novel process (100) for preparing biodegradable films for packaging that utilizes sustainable and efficient methods. The process (100) comprises several steps: milling botanical components (101) using a dry milling machine (102) to separate foreign materials, wherein the milling process occurs over a time period of 2 to 5 hours at temperatures ranging from 40 to 70 degrees Celsius. The botanical components include coconut husk (5%-10%), rice husk (5%-10%), bamboo fiber (5%-15%), Chondrus extract (25%-40%), and agar (25%-40%), all of which are sourced from the market.
[0016] In another aspect, the process (100) includes mixing (103) the milled botanical components using an agitator mixer at speeds of 550 to 750 rpm and temperatures between 40 and 55 degrees Celsius to ensure uniformity.
[0017] In another aspect, polymers for plasticization (104) are added to the mixture, which comprises a combination of polylactide (35%-50%), polyvinyl alcohol (15%-25%), and polyglycolic acid (25%-35%).
[0018] In yet another aspect, a stabilizer (105) is incorporated into the mixture to enhance thermal stability and promote cross-linking between the botanical components and polymers. The stabilizer consists of calcium chloride (10%-20%), tris(nonylphenyl) phosphite (30%-45%), and glycerin/polyglycerin (30%-45%).
[0019] In another aspect, the mixture is subjected to melting (106) in a melting unit with a sheet die at temperatures ranging from 160 to 320 degrees Celsius, under pressures between 1500 and 4000 psi, ensuring an optimal melt flow rate of 0.02 grams/10 min to 1.2 grams/10 min for forming the films.
[0020] The final biodegradable film produced through this process exhibits high tensile strength ranging between 32.45 to 57.63 N/m² and high impact strength between 53 to 64 J/cm.
[0021] In another aspect, the biodegradability of the films is tested through composting at room temperature, achieving 100% degradation within 90 to 250 days, making the films capable of decomposing naturally under various conditions.
[0022] Overall, the invention provides a highly efficient process for producing biodegradable films that are not only flexible and durable but also environmentally friendly. By utilizing renewable resources and advanced formulation techniques, this process addresses the limitations of prior art, enhancing the performance characteristics of biodegradable packaging materials while minimizing their environmental footprint.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitutes a part of this specification. The drawings illustrate exemplary embodiment of the present disclosure and, together with the, serve to explain the principles of the present disclosure.
[0024] Figure 1 illustrates a block diagram of the process (100) for preparing biodegradable films.
[0025] Figure 2 illustrates the dry milling machine (102) used for milling botanical components.
[0026] Figure 3 illustrates the agitator mixer in which the milled botanical components are mixed.
DETAILED DESCRIPTION
[0027] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents.
[0028] The present invention provides a process (100) for preparing biodegradable film for packaging. Figure 1 illustrates a block diagram of the process (100) for preparing biodegradable films. It depicts the sequence of steps, including milling of botanical components (101), mixing of the milled components (103), addition of polymers (104), addition of stabilizers (105), and the final film formation in a melting unit. The figure shows the integration of various components to ensure an efficient and environmentally friendly biodegradable film producing process.
Process steps for preparing biodegradable film:-
[0029] The process (100) comprises several steps:
Milling of botanical components (101) where the botanical components are selected for their renewable nature and high biodegradability. The botanical components include coconut husk in an amount of 5%-10% by weight, rice husk in an amount of 5%-10% by weight, bamboo fiber in an amount of 5%-15% by weight, Chondrus extract in an amount of 25%-40% by weight, and agar in an amount of 25%-40% by weight. All the botanical components and other chemicals are purchased from market.
[0030] These components are milled in a dry milling machine (102) for 2-5 hours at a temperature between 40°C and 70°C. The milling process ensures that the botanical components are finely ground and prepared for the subsequent steps. Figure 2 provides a detailed view of the dry milling machine (102) used for milling botanical components. It highlights how the botanical materials, such as coconut husk, rice husk, bamboo fiber, Chondrus extract, and agar, are ground to a fine consistency, ready for further processing.
[0031] Mixing (103) of Botanical Components where the milled botanical components are then mixed in an agitator mixer at a speed of 550-750 rpm and a temperature between 40°C and 55°C. This mixing process ensures the even distribution of the botanical fibers, enhancing their integration with the polymer materials in later stages. Figure 3 illustrates the agitator mixer in which the milled botanical components are mixed (103). This figure showcases the uniform blending process, with the botanical fibers being distributed evenly to improve their integration with the polymer matrix.
[0032] Addition of combinationof Polymer for Plasticization (104) is the step to improve the flexibility and durability of the film where a combination of polymers is added to the mixture of botanical components. The polymers used in this invention includes polylactide in an amount of 35%-50% by weight, polyvinyl alcohol in an amount of 15%-25% by weight, and polyglycolic acid in an amount of 25%-35% by weight. The addition of these polymers (104) enhances the plasticization of the mixture, allowing for a flexible and durable film.
[0033] Addition of a Stabilizer combination (105) where a combination of stabilizer are incorporated into the mixture to enhance the thermal stability and to promote cross-linking between the botanical components and the polymers. The stabilizer consists of calcium chloride in an amount of 10%-20% by weight, tris(nonylphenyl) phosphite in an amount of 30%-45% by weight and, glycerin or polyglycerin in an amount of 30%-45% by weight. This combination stabilizes the film during processing and enhances the bonding between the botanical and polymeric components.
[0034] Melting and Formation of the Film (106) where the final mixture is melted in a melting unit at a temperature ranging from 160°C to 320°C and a pressure between 1500 and 4000 psi. The melting unit is equipped with a sheet die for forming the final biodegradable film. The melting unit controls temperature and pressure, ensuring optimal conditions for forming flexible, durable films. The melt flow rate is maintained between 0.02 grams/10 min and 1.2 grams/10 min, which is optimized to form uniform films with high mechanical strength. The resulting biodegradable film has enhanced physical properties suitable for packaging applications.

EXPERIMENTS AND RESULTS
[0035] Samples of the biodegradable film were prepared from the disclosed process. Table 1 illustrates the botanical components of the prepared sample biodegradable film for packaging as per the disclosed process.
Table 1: Botanical components in sample biodegradable film prepared from the process

Component Film F1 (%) Film F2 (%) Film F3 (%)
Coconut husk 10 5 10
Rice husk 5 10 10
Bamboo fibre 10 15 10
Chondrus Extract 40 30 35
Agar 35 40 35

[0036] Table 2 illustrates the polymer and stabilizer combination of the prepared sample biodegradable film for packaging as per the disclosed process.
Table 2: Polymer and stabilizer combination in sample biodegradable film prepared from the process

Biodegradable film Polymer combination Stabilizer combination
Film F1 40% Polylactide, 25% Polyvinyl alcohol, 35% Polyglycolic acid 20% Calcium chloride, 45% Tris(nonylphenyl) phosphite, 35% Glycerin/polyglycerin
Film F2 45% Polylactide, 20% Polyvinyl alcohol, 35% Polyglycolic acid 10% Calcium chloride, 45% Tris(nonylphenyl) phosphite, 45% Glycerin/polyglycerin
Film F3 50% Polylactide, 20% Polyvinyl alcohol, 30% Polyglycolic acid 15% Calcium chloride, 40% Tris(nonylphenyl) phosphite, 45% Glycerin/polyglycerin

[0037] Table 3 illustrates the results of the mechanical properties of the biodegradable film produced through this process.
Table 3: Mechanical properties of the biodegradable film produced through the disclosed process

Biodegradable film Tensile strength (N/m²) Impact strength (J/cm)
F1 46.92 61
F2 57.63 64
F3 32.45 53

[0038] The mechanical properties of the biodegradable film produced through this process were tested. The biodegradable film produced through the process exhibits high tensile strength ranging between 32.45 to 57.63 N/m² and high impact strength between 53 to 64 J/cm.
[0039] The biodegradability of the films is tested through composting at room temperature, achieving 100% degradation within 90 to 250 days, making the films capable of decomposing naturally under various conditions. This means that the biodegradable film produced through the process can degrade naturally with or without industrial facilities and/or thermal processing over a relatively short period of time. This is due to the reason that we are utilizing botanical components with high protein content in biodegradable products which can significantly enhance their degradation rate. The increased protein levels contribute to higher bioavailable nitrogen and phosphorus, essential nutrients that boost microbial activity. This promotes faster biodegradation, making the products more effective in composting and other non-industrial environments.
[0040] Advantages of the process for preparing biodegradable film for packaging:
• Sustainable Resources: The process incorporates renewable and botanical components, ensuring that the raw materials for the films are both sustainable and environmentally friendly. This reduces reliance on non-renewable fossil fuels, contributing to a more sustainable production cycle.
• Advanced Formulation Techniques: The use of advanced formulation techniques during the process enhances the overall properties of the biodegradable films, leading to improved flexibility, durability, and mechanical performance, making them suitable for a wide range of packaging applications.
• Improved Biodegradation: The process is optimized to promote rapid biodegradation of the films, ensuring their efficient breakdown in different environmental conditions. This leads to an eco-friendlier disposal, minimizing long-term waste accumulation.
• Performance and Environmental Benefits: The combination of renewable resources and cutting-edge formulation techniques results in films that offer superior performance during use while significantly reducing their environmental impact. This makes the films both highly functional and eco-conscious, aligning with the growing demand for sustainable packaging solutions
[0041] Overall, the invention provides a highly efficient process for producing biodegradable films that are not only flexible and durable but also environmentally friendly. The biodegradable film prepared from the disclosed process has high tensile strength, High impact strength, and transparency, all of which are beneficial flexible film packaging characteristics. By utilizing renewable resources and advanced formulation techniques, this process addresses the limitations of prior art, enhancing the performance characteristics of biodegradable packaging materials while minimizing their environmental footprint.
[0042] Although the present invention has been particularly described with reference to implementations discussed above, various changes, modifications and Substitutes are can be made. Accordingly, it will be appreciated that in numerous instances some features of the invention can be employed without a corresponding use of other features. Further, variations can be made in the number and arrangement of components illustrated in the figures discussed above.
, Claims:I/We Claim:
1. A process (100) for preparing a biodegradable film for packaging, comprising the steps of:
milling (101) a plurality of botanical components in a dry milling machine (102) for 2-5 hours;
mixing (103) milled plurality of botanical components in an agitator mixer;
adding a polymer combination (104) to the mixture for plasticization;
adding a stabilizer combination (105) into the mixture to enhance thermal stability and cross-linking of the plurality of botanical components with the polymer; and
melting (106) the resulting mixture in a melting unit with a sheet die to obtain a biodegradable film.
2. The process (100) as claimed in claim 1, wherein the milling (101) of the plurality of botanical components including coconut husk in an amount of 5%-10% by weight, rice husk in an amount of 5%-10% by weight, bamboo fiber in an amount of 5%-15% by weight, Chondrus extract in an amount of 25%-40% by weight, and agar in an amount of 25%-40% by weight.
3. The process (100) as claimed in claim 1, wherein the milling (101) of the plurality of botanical components in the dry milling machine at a temperature ranging between 40°C and 70°C.
4. The process (100) as claimed in claim 1, wherein the mixing (103) the milled plurality of botanical components in an agitator mixer at a speed of 550-750 rpm and a temperature between 40°C and 55°C.
5. The process (100) as claimed in claim 1, wherein adding the polymer combination (104) to the mixture for plasticization having a combination of polylactide in an amount of 35%-50% by weight, polyvinyl alcohol in an amount of 15%-25% by weight, and polyglycolic acid in an amount of 25%-35% by weight.
6. The process (100) as claimed in claim 1, wherein the adding the stabilizer combination (105) to the mixture having a combination of calcium chloride in an amount of 10%-20% by weight, tris(nonylphenyl) phosphite in an amount of 30%-45% by weight, and glycerin or polyglycerin in an amount of 30%-45% by weight.
7. The process (100) as claimed in claim 1, wherein melting (106) the resulting mixture in the melting unit with the sheet die at a temperature ranging between 160°C to 320°C.
8. The process (100) as claimed in claim 1, wherein melting (106) the resulting mixture in the melting unit with the sheet die at a pressure of 1500 to 4000 psi.
9. The process (100) as claimed in claim 1, wherein melting (106) the resulting mixture in the melting unit with the sheet die having the melt flow rate ranging between 0.02 grams/10 min and 1.2 grams/10 min to form the biodegradable film.
10. The process (100) as claimed in claim 1, wherein the biodegradable film prepared from the process exhibits a tensile strength ranging from 32.45 N/m² to 57.63 N/m²; and an impact strength ranging from 53 J/cm to 64 J/cm.

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