COMPOSITION AND METHOD FOR THE PRODUCTION OF PLANT-BASED BIOPLASTICS

Abstract

COMPOSITION AND METHOD FOR THE PRODUCTION OF PLANT-BASED BIOPLASTICS ABSTRACT The invention presents a composition and method for producing plant-based bioplastics from renewable resources. The method involves extracting biopolymers from agricultural byproducts, blending them with biodegradable synthetic polymers, and incorporating natural additives to enhance mechanical properties and biodegradability. This novel formulation improves the strength and flexibility of bioplastics while promoting sustainability by utilizing waste materials. The bioplastics produced are fully biodegradable and suitable for various applications, addressing the pressing need for environmentally friendly alternatives to conventional plastics. This invention contributes to waste reduction and supports the transition to sustainable materials in multiple industries.

Specification

Description:COMPOSITION AND METHOD FOR THE PRODUCTION OF PLANT-BASED BIOPLASTICS

FIELD OF THE INVENTION

The present invention relates to bioplastics, specifically to a composition and method for producing plant-based bioplastics derived from renewable resources. This invention is particularly relevant in the fields of materials science, sustainable manufacturing, and environmental technology, aiming to reduce dependency on fossil fuels and enhance biodegradability.
BACKGROUND OF THE INVENTION

With the increasing awareness of environmental issues and the impact of plastic waste on ecosystems, there has been a significant push toward developing biodegradable alternatives to conventional plastics. Traditional plastics, derived from petrochemical sources, contribute to pollution and long-lasting waste in landfills and oceans. In response, bioplastics, which are either biodegradable or made from renewable biomass sources, have emerged as a viable solution.
Bioplastics can be produced from a variety of materials, including starch, polylactic acid (PLA), polyhydroxyalkanoates (PHA), and proteins. However, existing methods for producing plant-based bioplastics often face challenges such as high production costs, limited availability of raw materials, and insufficient mechanical properties for various applications. Therefore, there is a critical need for a novel composition and method that can enhance the properties of plant-based bioplastics while being economically viable.
The current research aims to address these challenges by utilizing specific plant-based materials in a unique formulation. This invention seeks to optimize the production process, reduce reliance on fossil fuels, and improve the biodegradability of bioplastics, ultimately contributing to a more sustainable future.


SUMMARY OF THE INVENTION

The invention provides a composition for producing plant-based bioplastics comprising a blend of renewable plant materials, biodegradable polymers, and natural additives to enhance mechanical properties and biodegradability. The method involves extracting biopolymers from specific plant sources, blending them with biodegradable polymers, and processing them under controlled conditions to form bioplastic materials.
This innovative composition not only enhances the mechanical strength and flexibility of the resulting bioplastic but also ensures that the materials are fully biodegradable, addressing the critical issues of plastic pollution. The invention outlines specific ratios and processing conditions to achieve optimal performance, making it suitable for various applications, including packaging, automotive components, and consumer products.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying figures where like reference numerals refer to identical or functionally similar elements throughout the separate views and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the invention.
The method figure illustrates the process flow for producing plant-based bioplastics. The process begins with the selection and extraction of biopolymers from chosen plant sources, followed by mixing these with biodegradable polymers and natural additives. The mixture is then subjected to specific processing conditions, including temperature and pressure, to form the bioplastic. Finally, the product undergoes quality testing to ensure compliance with industry standards.
Skilled artisans will appreciate the elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While various embodiments of the invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions may occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed. It shall be understood that different aspects of the invention can be appreciated individually, collectively, or in combination with each other.
The invention encompasses a novel composition and method for producing plant-based bioplastics, emphasizing the use of renewable plant materials. In an embodiment, the composition includes plant fibers, such as cellulose or hemicellulose, sourced from agricultural byproducts like corn stover, sugarcane bagasse, or wheat straw. These fibers serve as a reinforcement material to enhance the mechanical properties of the bioplastic.
The biopolymer extraction process is critical to the invention. It involves breaking down plant materials using environmentally friendly solvents or enzymatic treatments to obtain biopolymers that can serve as a matrix in the bioplastic formulation. The extracted biopolymers can be combined with biodegradable synthetic polymers like PLA or PHA in specific ratios. This blend results in a composite material that exhibits desirable characteristics for commercial applications.
In another embodiment, natural additives, such as glycerol or natural waxes, are incorporated into the composition. These additives not only improve the flexibility and processability of the bioplastic but also enhance its biodegradability. The selection of these additives is crucial to ensure compatibility with the biopolymer matrix and to achieve the desired properties.
The processing stage involves melting and mixing the components under controlled conditions, which can include varying temperature and pressure settings. The processing method can include extrusion, injection molding, or compression molding, depending on the intended application. Each method's parameters can be adjusted to optimize the physical and mechanical properties of the final product.
After processing, the bioplastic is cooled and solidified. The resulting product can be formed into sheets, films, or specific shapes suitable for different applications. Importantly, the bioplastic's biodegradability is assessed through standardized testing methods, ensuring it meets regulatory requirements for compostability.
The invention not only offers a sustainable alternative to traditional plastics but also supports waste reduction by utilizing agricultural byproducts that would otherwise contribute to landfill waste. Additionally, the innovative composition enables the production of bioplastics with mechanical properties comparable to conventional plastics, making them suitable for a wide range of consumer and industrial applications.
Moreover, the environmental impact of producing plant-based bioplastics is significantly lower than that of traditional plastic production. The raw materials used are renewable and contribute to carbon sequestration during their growth, thus minimizing the carbon footprint associated with the manufacturing process. This aligns with global sustainability goals and presents an attractive option for environmentally conscious consumers and industries.
The bioplastics produced through this method can be utilized in various sectors, including packaging, automotive, and construction, where lightweight, durable, and biodegradable materials are in high demand. This versatility enhances the market potential for the invention, promoting broader adoption of sustainable practices across multiple industries.
Example Embodiment 1: Corn Stover-Based Bioplastic
In an embodiment, the plant-based bioplastic composition utilizes corn stover as the primary renewable resource. The method begins with the collection of corn stover, which includes stalks, leaves, and husks, typically left in the field after harvest. The corn stover is subjected to a pulping process using environmentally friendly solvents, such as ionic liquids, to extract cellulose and hemicellulose, which serve as the primary biopolymers.
The extracted cellulose is then blended with a biodegradable synthetic polymer, specifically polylactic acid (PLA), in a ratio of 70% cellulose to 30% PLA. To enhance flexibility, natural additives such as glycerol (5% by weight) and beeswax (2% by weight) are incorporated into the mixture.
The blend undergoes processing through a twin-screw extruder, where it is heated to 180°C to facilitate uniform melting and mixing. The extruder is equipped with a cooling system that allows for controlled cooling and solidification of the extruded sheets. The resulting bioplastic exhibits improved tensile strength and flexibility compared to PLA alone, making it suitable for packaging applications, such as biodegradable bags and food containers.
After production, the biodegradability of the corn stover-based bioplastic is tested using ASTM D6400 standards, demonstrating complete degradation within 90 days in composting conditions.
Example Embodiment 2: Sugarcane Bagasse Bioplastic
In another embodiment, the composition focuses on utilizing sugarcane bagasse, a byproduct of sugar production, as the primary source for bioplastic production. The process begins with the collection of dried sugarcane bagasse, which is then subjected to an enzymatic treatment using cellulase enzymes to break down the fibrous structure and extract soluble sugars and cellulose.
The extracted cellulose is blended with polyhydroxyalkanoate (PHA), a biodegradable polymer, at a ratio of 60% cellulose to 40% PHA. To improve the processing characteristics, natural additives such as chitosan (3% by weight) and coconut oil (1% by weight) are added to the mixture, enhancing its moisture resistance and flexibility.
The composite mixture is processed using an injection molding technique, allowing for the formation of complex shapes suitable for consumer products, such as biodegradable cutlery and containers. The injection molding process is conducted at a temperature of 160°C, followed by rapid cooling to solidify the molded items.
Post-production testing reveals that the sugarcane bagasse bioplastic maintains comparable mechanical properties to conventional plastics, with a notable advantage in biodegradability, meeting ISO 17088 standards and decomposing within 60 days in composting environments.
Advantages of the Invention
The invention offers several advantages over existing bioplastic formulations and production methods, including:
1. Enhanced Mechanical Properties: The unique composition improves the strength and flexibility of bioplastics, making them suitable for a wider range of applications.
2. Utilization of Renewable Resources: By sourcing raw materials from agricultural byproducts, the invention promotes sustainability and reduces waste.
3. Cost-Effectiveness: The method is designed to be economically viable, allowing for large-scale production without compromising quality.
4. Biodegradability: The resulting bioplastic materials are fully biodegradable, contributing to waste reduction and environmental sustainability.
5. Versatility: The bioplastics can be tailored for various applications, meeting industry-specific requirements.
, Claims: 
I/WE CLAIM:
Claim: A method for producing plant-based bioplastics, comprising the steps of:
(a) extracting biopolymers from renewable plant materials;
(b) blending the extracted biopolymers with biodegradable synthetic polymers;
(c) incorporating natural additives into the blend;
(d) processing the blend under controlled conditions to form the bioplastic;
(e) cooling and solidifying the bioplastic for subsequent applications.
Dependent Claim 1: The method of claim 1, wherein the renewable plant materials are selected from the group consisting of corn stover, sugarcane bagasse, and wheat straw.
Dependent Claim 2: The method of claim 1, wherein the biodegradable synthetic polymers are polylactic acid (PLA) or polyhydroxyalkanoates (PHA).
Dependent Claim 3: The method of claim 1, wherein the natural additives are glycerol or natural waxes to improve flexibility.
Dependent Claim 4: The method of claim 1, wherein the processing step includes extrusion, injection molding, or compression molding.
Dependent Claim 5: The method of claim 1, wherein the bioplastics are assessed for biodegradability according to standardized testing methods.
Dependent Claim 6: The method of claim 1, wherein the processing conditions are adjusted to optimize the physical and mechanical properties of the bioplastic.

Dependent Claim 7: The method of claim 1, wherein the bioplastics produced are used in packaging, automotive components, or consumer products.

Documents