The push for safer and more sustainable materials has never been more urgent, particularly in the realm of plastics. A Joint Industry Project (JIP) between iCAST and Central Plains Group (CPG), a leader in regenerative agriculture and biopolymer production, has made significant progress in developing glycerol-free thermoplastic starch (TPS), a key step towards creating sustainable bioplastics. This innovative project addresses the pressing need to eliminate glycerol as a plasticiser, reducing the associated health and environmental risks while advancing the performance of bioplastics.
Challenges with current TPS, bioplastics and the need for blends
Glycerol has traditionally been used as a plasticiser in the production of TPS due to its ability to improve flexibility. However, its use comes with several drawbacks. During processing, glycerol undergoes thermal degradation, releasing harmful toxins such as acetaldehyde, acrolein, and BTEX compounds (benzene, toluene, ethylbenzene, and xylene). These substances pose significant health risks to both workers and consumers. Additionally, the production of glycerol has a considerable carbon footprint, contributing approximately 2kg of COā‚‚ equivalent per kilogram. Given the increasing focus on sustainability, finding alternatives to glycerol is a crucial challenge for the industry.
On the other hand, current bioplastics, including TPS, often face limitations in mechanical properties, water sensitivity, and thermal stability, making them less practical for many applications. TPS, for instance, is biodegradable and derived from renewable sources, but it is rarely used in its pure form due to its inherent weaknesses, such as brittleness and low moisture resistance. To improve functionality and sustainability, TPS is commonly blended with other biopolymers like PBAT, PLA, and PHAs. These blends combine complementary properties, enhancing strength, flexibility, and durability while maintaining biodegradability. Developing optimised TPS blends with biopolymers offers a promising pathway for creating more versatile and sustainable materials tailored to diverse applications.
Initial success and the next steps
Thermoplastic starch
CPG, in collaboration with iCAST, is spearheading the development of a low-carbon, zero-waste circular bio-economy. The Biopolymer Innovation Hub, established by CPG in the UK with a $500,000 investment, is central to this mission. This state-of-the-art facility brings together commercial partners and leading academics to explore innovative uses for thermoplastic starch-based biopolymers.
The JIPā€™s initial phase demonstrated the feasibility of replacing glycerol with a range of alternative sustainable plasticisers. These alternatives not only enhance the thermal stability of TPS but also pave the way for safer, more versatile, and cost-effective bioplastics. By eliminating or significantly reducing glycerol content, the project has the potential to save up to 60,000 tons of COā‚‚ equivalent annually by 2027, a significant step towards achieving global sustainability goals.
Next steps and future potential
Building on its early success on developing the eco-friendly TPS formulations in lab scale, the projectā€™s next phase will focus on pilot-scale trials to refine new TPS formulations, with iCAST playing a key role in characterising these formulations for commercial use. This stage also aims to blend the improved TPS with other biopolymers to expand its applications, particularly in the compostable packaging and agricultural sectors. These advancements have the potential to transform the bioplastics industry by:
- Enhancing the safety and performance of bioplastics.
- Reducing environmental impact through lower COā‚‚ emissions.
- Creating new economic opportunities across the bioplastics value chain.
This collaboration between iCAST and CPG is not only improving the safety and sustainability of thermoplastic starch but also aligning with global efforts to combat climate change. As the project progresses, it promises to set new standards for the bioplastics industry, benefiting both people and the planet.
Anton Mialkin, CPG’s Biopolymer Engineer, said, “Our joint industry project with iCAST has been successfully completed. The access to research facilities for developing our sustainable biopolymers, combined with the expertise of the iCAST team, has been useful in progressing to the pilot trial stage. We anticipate further collaboration with iCAST to bring our biopolymers to commercial applications.”
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