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A research project has developed a bio-based plastic film with significantly improved barrier properties against oxygen and water vapour for food packaging. This was reported by the Fachagentur Nachwachsende Rohstoffe e.V. (Agency for Renewable Resources).
Plastic packaging films are flexible, stretchable and waterproof and airtight - a true marvel of technology! In order to fulfil all these functions, they often consist of several layers of different types of plastic such as multilayer films - which, however, makes them much more difficult to recycle.
However, barrier functions can also be achieved by coating the base film. This is the approach taken by the research consortium „Development of novel bio-based films with special barrier properties for applications in the food and packaging sector“ (BioBaFol). The companies and research institutions involved in the research network were Tecnaro GmbH, Fraunhofer Institute for Silicate Research (ISC), Südpack Verpackungen GmbH & Co. KG, JenCAPS Technology GmbH and SKZ - KFE gGmbH. They had set themselves the goal of developing a high-performance barrier film made from just one bio-based film material (PLA) and one functional layer (bioORMOCER®). The clear requirement was that the biobased content of the finished film should be at least 80 per cent
Bio-based replacement for multilayer films
After three and a half years of research, a prototype of a new type of bio-based film based on PLA and bioORMOCER® is now available, which has a higher overall barrier effect against oxygen and water vapour than the uncoated base film. The sustainability assessment shows a reduction in greenhouse gas potential with a lower film thickness thanks to less material consumption and the recycling of production waste in the manufacturing process - which would not be possible with petroleum-based multilayer films.
On the way to industrial production of the new bio-based barrier films, the processing of the PLA compound and the bioORMOCER® synthesis have been successfully scaled up from the laboratory to an industrial scale. The scientists involved are therefore optimistic about future commercial utilisation.
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