Sustainable and Compostable packaging from sea; a Circular economy

Abstract

ABSTRACT The proposed method investigates the development of a sustainable and compostable packaging material derived from marine algae. By harnessing the potential of this abundant and renewable resource, this study aims to address the pressing issue of plastic pollution while promoting a circular economy. The proposed packaging solution offers an eco-friendly alternative to traditional petroleum-based plastics, with a focus on biodegradability and compostability to minimize environmental impact. Through a comprehensive approach encompassing material extraction, processing, and performance evaluation, this research seeks to contribute to the development of sustainable packaging solutions that align with the principles of circular economy. "It aims to use this plastic in sustainable farming, employing it as a compost or fertilizer to promote plant growth. In agriculture, it is widely used for mulching and protecting crops against pests. To enhance its various properties, it can be reinforced with composites such as cotton or jute." This reinforced plastic can be used in industrial purposes like making drums, cans etc.

Specification

Description:Sustainable and Compostable packaging from sea; a Circular economy


Field of Invention:
In the field of invention, the project focuses on developing environmentally friendly agricultural practices through the innovative use of biodegradable bio-plastics. Traditional mulching plastics, while effective in controlling pests and unwanted crops, contribute significantly to environmental pollution due to their persistence in the ecosystem. This project introduces a novel approach by utilizing bio-plastics derived from red algae (agar), glycerol, spirulina, water, and cellulose (cotton) as a sustainable alternative.These bio-plastics not only serve the functional role of traditional mulch by suppressing weeds and pests but also offer the advantage of biodegradability. Upon decomposition, they enhance soil fertility by breaking down into beneficial organic matter, which supports plant growth. This invention represents a significant advancement in agricultural technology, merging economic efficiency with environmental stewardship and reducing the reliance on harmful chemical fertilizers and non-degradable plastics.

Background:
Petroleum-based plastics, renowned for their versatility, are increasingly produced to meet growing consumer demand. Unfortunately, their non-biodegradable nature contributes significantly to environmental pollution, accumulating in landfills, waterways, and oceans. These plastics gradually break down into microplastics, infiltrating the food chain and posing risks to wildlife and human health. Improper waste disposal and a lack of public awareness exacerbate the issue.
To address this crisis, researchers are exploring renewable alternatives. Bio-plastics, derived from sources like plants, bacteria, and algae, offer a promising solution. Algae, in particular, stand out due to their abundance and rich polysaccharide content. This biopolymer can be transformed into biodegradable, high-quality plastics. While bio-plastic production is still in its growth phase, with global output reaching 368 million tonnes in 2019, it represents a substantial step towards a sustainable future. However, the COVID-19 pandemic caused a slight decline in plastic production in 2020.
This research aims to delve deeper into the potential of algae-based bio-plastics. By combining algae with starch and cellulose and incorporating plasticizers, we seek to develop innovative materials with superior properties. This study will compare the characteristics of these bio-films and explore their potential applications.
Statement of Invention:
This invention pertains to a novel bio-plastic formulation specifically designed for agricultural mulching. The bio-plastic is composed of a unique combination of red algae (agar), glycerol, spirulina, water, and cellulose (cotton). Unlike traditional mulching plastics, this bio-plastic is fully biodegradable and decomposes into organic matter that enriches the soil, thereby enhancing plant growth. It provides effective weed suppression and pest control, reduces the need for additional fertilizers, and minimizes environmental impact by breaking down naturally. This innovative approach offers both ecological and economic benefits, advancing sustainable agricultural practices.
Summary:
This invention introduces a novel bio-plastic for agricultural mulching, formulated from a distinctive blend of red algae (agar), glycerol, spirulina, water, and cellulose (cotton). Unlike traditional mulching plastics, which are environmentally harmful, this bio-plastic is biodegradable and decomposes into organic matter that enhances soil fertility. It effectively suppresses weed growth and pest infestations while simultaneously enriching the soil with nutrients as it breaks down. This dual functionality not only reduces the need for additional pest control and fertilizers but also contributes to sustainable agricultural practices by minimizing plastic waste and supporting plant growth.

US7235594B2
The present invention relates to biodegradable plastic composition comprising rice powder and/or corn powder, which can be characterized in comprising 100 parts by weight of polyolefin matrix resin; 5 to 400 parts by weight of grain powder selected from the group consisting of rice powder, corn powder and mixture thereof. The biodegradable plastic composition according to the present invention can be manufactured in various forms such as injection molding product, sheet molding and blow molding product, which have excellent physical properties and product stability. The efficiency of waste disposable of the product manufactured with the composition can be remarkably improved since the rive powder or the corn powder contained in the composition can be degraded by microbes in the nature after a certain period. Therefore, the problems of soil, air, and sea pollution caused by burial or incineration of the wastes of conventional plastic molding product can be minimized.
US10919203B2
Described herein are strength characteristics and biodegradation of articles produced using one or more petrochemical-based polymers and one or more carbohydrate-based polymers. A compatibilizer can optionally be included in the article. In some cases, the article can include a film or bag.

WO2019155398A1
This invention relates to a biodegradable plastic and a process for producing the biodegradable plastic from bio-based polymers and agricultural by-products renewable resource based. The biodegradable plastic is produced in a process comprising melt blending a polymer blend comprising or consisting of polybutylene succinate (PBS); and at least one other bio-based polymer. The other bio-based polymer may be a biopolyester such as polybutylene adipate co-terephthalate (PBAT) or polylactic acid (PLA) or poly hydroxy butyrate (PHB) or thermoplastic starch which may be modified.
EP2668105A1
Disclosed herein is a sustainable article substantially free of virgin petroleum-based compounds that includes a container, a cap, and a label, each made from renewable and/or recycled materials. The article has a shelf life of at least two years, and is itself entirely recyclable. The container can include polyethylene, polyethylene terephthalate, or polypropylene. The cap can include polypropylene or polyethylene. The label can include polyethylene, polyethylene terephthalate, polypropylene, or paper.
US20070129467A1
A biodegradable polymer composition useful for manufacturing biodegradable items or articles with improved mechanical properties comprising poly(lactic acid) polymer (PLA), starch and protein material, obtainable by providing poly(lactic acid) polymer (PLA), starch and protein material in such ratios that PLA/starch blend represents at least 95% weight of the above three components and that starch represents at least 23% weight of PLA; mixing the above three components at room temperature in a controlled moisture atmosphere to afford a homogeneous mixture; subjecting the above homogeneous mixture to extrusion compounding under controlled heat, speed and pressure conditions; and drying down to a maximum of approximately 1% weight of moisture and subsequently conditioning the extruded polymeric composition.
Complete Description:
1. Source of Agar and Carrageenan: Red algae are rich in polysaccharides like agar and carrageenan. These substances are widely used in the food industry as thickeners and gelling agents, but they also have applications in bio-plastics. Agar and carrageenan can be used as bio-based materials in the creation of bio-plastics, helping to reduce reliance on petroleum-based plastics.
"Agar, a substance commonly used in plant tissue culture, could potentially benefit plant growth after decomposition of this kind of plastic. However, further research is needed to determine its specific effects and optimize its use as a soil amendment."
2. Spirulina: "Spirulina platensis, a microalgae known for its adaptability to extreme environments, has emerged as a promising alternative to traditional petroleum-based plastics. Its high protein content and ability to be processed into bio-plastics make it a sustainable and biodegradable option. Research has shown that Spirulina can be blended with various polymers to create bio-plastics with desirable properties, such as tensile strength, flexibility, and biodegradability. These bio-plastics have potential applications in packaging, consumer goods, and agricultural products, offering a more environmentally friendly .
Composition of Spirulina:
Component Percentage
Proteins 55-70%
Carbohydrates 15-25%
Lipids(Fats) 5-8%
Water Content Less than 10%(dry form)
Iron 2-7%
Magnesium 0.5-1%
Potassium 1-2%

3. Plasticizer: Glycerol, a versatile compound, plays a crucial role in the production of compostable plastics. As a plasticizer, it enhances the flexibility, processability, and biodegradability of these materials. By incorporating glycerol into biodegradable polymers like PLA, PHAs, or cellulose-based plastics, manufacturers can create compostable products with desirable properties, such as strength, flexibility, and the ability to decompose naturally in the environment. This makes glycerol an important component in the development of sustainable and eco-friendly."
"Glycerol, a versatile compound, can be used as a growth medium for certain plants. So, after decomposition of this kind of plastic they are used as a compost for plant.

Processing and Extraction:
1. Algae Extraction and Processing
• Harvesting: Red algae is typically harvested from marine environments, ensuring sustainability and minimizing environmental impact.
• Extraction: The algae is processed to extract the desired components, such as carrageenan, a polysaccharide that acts as a natural gelling agent.
• Purification: The extracted components are purified to remove impurities and ensure the quality of the final product.
"The production of microalgae-polymer blends typically involves compression molding or solvent casting. In compression molding, a mixture of biomass, polymers, and additives is heated and compressed to form bio-composites. Solvent casting involves dissolving the components in a solvent, casting the solution, and drying. While compression molding is often the preferred method due to its versatility and scalability, solvent casting can be simpler and more cost-effective for smaller-scale production. Other methods, such as injection molding and twin-screw extrusion, have also been explored for producing microalgae-polymer blends.
2. Bio-plastic Formulation
• Mixing: The purified carrageenan is mixed with other biodegradable polymers, such as polylactic acid (PLA) or poly-hydroxybutyrate (PHB), to enhance the material's properties.
• Additives: Additives like plasticizers, colorants, and fillers may be added to customize the bioplastic's characteristics.
• Heating: The mixture is heated to a specific temperature to facilitate the bonding of the components and create a viscous solution.
3. Molding
• Mold Preparation: The desired shape or product is created using a mold, which can be made of various materials like silicone, metal, or 3D-printed polymers.
• Injection Molding: The heated, viscous bio-plastic solution is injected into the mold under high pressure. The material fills the mold cavity and cools down, solidifying into the desired shape.
• Extrusion Molding: For continuous production of long, uniform shapes like sheets or tubes, the bio-plastic is extruded through a die and cooled down to form the final product.
4. Cooling and Demolding
• Cooling: The molded product is allowed to cool down to room temperature, ensuring complete solidification.
• Demolding: Once cooled, the product is carefully removed from the mold.
5. Finishing
• Cutting: If necessary, the molded product can be cut or trimmed to achieve the desired size or shape.
• Packaging: The finished bio-plastic products can be packaged for distribution or further processing.
Composites Reinforcement:
To enhance the properties and strength of plastics for various applications, cellulose and resin composites are utilized. Cellulose sources like cotton, which contains over 95% cellulose, offer an effective and environmentally friendly reinforcement, as cotton is biodegradable. Jute is another plant-based option for reinforcing plastics. These cellulose-reinforced plastics find extensive use in agriculture, including mulching for soil moisture retention, plant protection against pests and weather, greenhouse construction, and packaging for agricultural products. On the other hand, resin-reinforced plastics are known for their durability and thermal stability, maintaining their integrity under high temperatures. This makes them ideal for industrial applications such as the manufacture of drums and cans. By integrating cellulose and resin, the resulting plastic composites not only achieve enhanced strength and functionality but also contribute to environmental sustainability.

Composition and Properties:

Component Typical Percentage Properties
Red Algae(Agar) 5-15% Provides gelling and thickening properties. Agar forms a gel-like structure when cooled, which contributes to the bio-plastic's flexibility and formability.
Glycerol 10-15% Acts as a plasticizer, improving the flexibility and workability of the bio-plastic. Glycerol helps reduce brittleness and enhances the material's elasticity.
Spirulina 1-3% Contributes colour (blue-green), nutritional value, and can enhance mechanical properties. It also adds to the bio-plastic's environmental benefits.
Water 60-70% Serves as a solvent to dissolve agar and gelatin, influencing the consistency and final texture of the bio-plastic.
Cellulose
(Reinforcement) 10-15% Provides added strength and rigidity. Cellulose, being a natural fiber, reinforces the bio-plastic, improving its structural integrity and resistance to deformation.


o Mechanical Strength: 5-20 MPa

o Tensile Strength: 10-30 MPa

o Flexibility: Elongation at break: 5-20%

o Degradability: 3-12 months

o Water Resistance: 10-30% water absorption

o Hardness: Shore A 30-60

o Transparency: 50-80% transmittance

o Density: 1.2-1.6 kg/m³

o Thermal Stability: Up to 80-120°C

Bio-plastics without reinforcement components, such as those made solely from red algae (agar), glycerol, spirulina, and water, tend to decompose more rapidly and are more readily used as plant compost compared to their cellulose-reinforced counterparts. This is because the natural materials in these bio-plastics break down more quickly in composting environments, enriching the soil with organic matter. The absence of reinforcement means that these bio-plastics are generally less durable but more compatible with composting processes. In contrast, cellulose-reinforced bio-plastics, which incorporate materials like cotton to enhance strength and rigidity, decompose more slowly. The added cellulose fibers can extend the decomposition time, potentially taking several months to over a year to fully break down. While these reinforced bio-plastics offer improved mechanical properties, their slower degradation rate can delay their integration into composting systems, affecting their overall compostability.
Circular Economy:
The circular economy offers a sustainable solution for compostable plastics. By designing products for easy composting, optimizing collection systems, and ensuring proper processing, we can reduce waste, improve soil health, and minimize greenhouse gas emissions. Implementing a circular economy for compostable plastics requires collaboration between governments, businesses, and consumers to develop the necessary infrastructure, standardize materials, and raise awareness about the benefits of this approach.
Bio-compostable plastics, derived from renewable plant-based materials, offer a sustainable solution for waste management. After decomposition, these plastics break down into nutrient-rich organic matter that can be used as a natural fertilizer or compost to enhance plant growth. This closed-loop process contributes to a more circular economy and reduces reliance on synthetic fertilizers.
Applications in smart agriculture:
1. Mulching Films: Suppress weeds and retain soil moisture; degrade naturally, reducing waste.
2. Plant Protection Covers: Shield plants from pests and weather; biodegradable and eco-friendly.
3. Greenhouse Films: Cover greenhouses to control growing conditions; break down without leaving waste.
4. Seedling Pots and Trays: Container for seedlings; decompose in soil, enhancing soil health.
5. Fertilizer and Pesticide Packaging: Reduce environmental impact with compostable packaging.
6. Plant Labels: Identifying labels that decompose with plant material.
7. Soil Erosion Control Mats: Prevent erosion and improve soil stability; degrade over time.
8. Drip Irrigation Tubes: Deliver water directly to plants and break down, minimizing waste.
Traditional mulching plastics are used to prevent pest infestations and unwanted crop growth but often lead to significant environmental issues.In contrast, using biodegradable plastic bags for mulching offers notable advantages. These bio-plastics decompose easily when irrigated, breaking down into organic matter that enriches the soil. This dual benefit makes them highly advantageous: they not only eliminate the need for additional pest control measures but also act as a natural fertilizer, reducing the need for chemical inputs. Thus, bio-plastic mulching not only cuts costs but also enhances soil health, providing an economical and environmentally friendly alternative.
These applications help in promoting sustainability and reducing environmental impact in agriculture.
LCA studies about compostable plastic:
LCA studies by Bussa et al.(2019) and Beckstrom(2019) on microalgae-based bio-plastics indicate that microalgae cultivation can offer environmental benefits compared to traditional plastic production. While microalgae-based bio-fuels may have slightly higher greenhouse gas emissions than fossil fuels, they have greater potential for improvement. Microalgae production systems often excel in land use efficiency but may face challenges in other areas like freshwater demand. By optimizing cultivation techniques and integrating bio-refinery approaches, the overall environmental performance of microalgae-based bio-plastics can be further enhanced, as highlighted by these LCA assessments.
, Claims:Claims:
1. A method of producing a biodegradable and compostable packaging material, comprising the steps of:
• Extracting a biopolymer from marine algae;
• Processing the extracted biopolymer to form a film or sheet;
• Optionally, reinforcing the film or sheet with a natural fiber;
• Shaping the film or sheet into a desired packaging configuration.
2. A sustainable and compostable packaging material derived from marine algae, consisting of:
• Red algae
• Glycerin
• Spirulina, optionally included
• Reinforcement agents like cellulose (Cotton or jute)
3. As claimed in claim 2, Red algae or agar-agar as primary components, providing natural gelling properties for biodegradable film formation.
4. As claimed in claim 2, Glycerin as a plasticizer to enhance flexibility and usability of the packaging material.
5. As claimed in claim 2, Spirulina optionally included, to reinforce the structure and add nutritional benefits.
6. As claimed in claim 1, the developed packaging can be employed in sustainable farming as mulch or fertilizer to promote plant growth.
7. As claimed in claim 1, the packaging material can be reinforced with natural fibers such as cotton or jute for enhanced mechanical properties and it can be utilized in industrial applications, such as the manufacture of drums, cans, and other containers.
8. As claimed in claim 1, the performance evaluation of the packaging material includes tests for durability, biodegradability, and functionality in agricultural applications.
9. The method of claim 1 aims to contribute to a circular economy by promoting the use of renewable resources and reducing plastic pollution.

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