BioplasticsIndustryReport

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Thecompostablessectorofthebioplasticsindustryhasbeenmakingsignificantinroads,
especiallywithstarchbasedandPLAresins.PartI
DebraDarby
BioCycleAugust2012,Vol.53,No.8,p.40

TheplasticsindustryintheU.S.datesbacktothelate1860s,whenCelluloidan
entirelynewmaterialmadefromamixofcellulosenitrateandcamphorwas
introduced.Althoughflammable,celluloidmovedintomanymarketsincluding
billiardballsandphotographicfilm.AfterWorldWarII,PhillipsPetroleumCompany
expandeditsproductlinewithnaturalgas,settingthestageforplastics.Itbegan
researchontheconversionofethyleneandpropylenegases,whichultimatelyledto
thediscoveryandtransformationofhydrocarbonsintoplastics,accordingtothe
AmericanChemicalSociety.Bythelate1970s,linearlowdensitypolyethylene
(LLDPE)wasintroduced.Consumermarketapplicationsincludedplasticbagsand
thinfilms.Todaythetraditionalplasticsindustryisawelloiledmachinewitha
matureglobalsupplychain.Consumeruseofplasticsisaroutinepartofdailylife.
Figure1.Market Bioplasticsafamilyofmaterialsthatarebiobased,biodegradable,orboth
introductionofplastics madetheirdebutinthelate1980s.Likeearlyplastics,bioplasticscanhavedifferent
propertiesrangingfromflexibletorigidandcanbeusedforawidevarietyof
disposableapplications,orsemidurableanddurableproducts.Biobasedplasticsarebeingusedinfibers,andin
automotive,electronics,toysandsportinggoodsproducts(amongothers),replacingtraditionalmaterials
includingpolypropylene(PP),highdensitypolyethylene(HDPE),andacrylonitrilebutadienestyrene(ABS).
Figure1summarizesthemarketevolutionofplasticssince1860.

Actualbiodegradabilityisbasedonabioplasticschemicalstructure,nottherawresourceused.Thereforeplastics
thatbiodegradecanbemadefromeitherpetroleumbasedorrenewablebiobasedresources.And
nonbiodegradableplasticscanbemadefromrenewableresources.Figure2illustratesthesevariousdistinctions,
aswellaswhetherbioplasticmaterialsarestructuredtoactuallybiodegrade.Biodegradablescanbeusedfor
agriculturalfilmsreplacingconventionalLLDPEfilmsandforhorticulturalapplicationslikeplantpots,traysand
planttagsreplacingconventionalPP.

Specificbioplasticmaterialsarebiodegradableinspecific
environments,e.g.,water,compostingandanaerobic
digestion.Bioplasticmaterialsneedtobeindependently
thirdpartytestedandcertifiedforbiodegradabilityboth
inthespecificenvironmentandfortheamountoftime
actuallyneededtobiodegradeinthatenvironment.
Compostabilityofabioplasticisdefinedasbiological
degradationunderindustrialcompostingconditionsdefined
byASTMD6400/EN13432standardspecificationsfor
compostableplastics,andASTM6868standardspecification
forplasticsascoatingstypicallyusedforpaper.ASTM7081
isastandardforbiodegradabilityinmarinewater
environments. Figure2.Bioplasticsclassificationsaccordingto
biobasedcontentandbiodegradability(Source:
bioplasticsMagazine)
IndustryOverview
Thestateofthebioplasticsindustry,andinparticular
compostables,canbetrackedbylookingatthevariousmarketsandapplicationstypicallydominatedbyearlier
traditionalplastic.Growthinconsumerdrivenmarkets,includingpackagingfilms,bagsandfoodservice
disposables,areimportantsignalsforthebioplasticsindustryascompostablesarebecomingmorecommonly
usedforpackaging,foodserviceandcatering.

Populationgrowthanddensityinurbanareasaredrivinglegislationforcompostablebagsandimplementationof
residentialorcommercialorganicsrecycling,aswellasbanningrestrictionsonsingleuseplasticsbags.Asrecent
asMay2012,theCityofLosAngelesbecamethelargestcityinthenationtoapproveabanonplasticbagsat
supermarketcheckouts.

TheEuropeanBioplasticsAssociationreportedglobalproductionof
bioplasticsreached725,000metrictonsin2010andisexpectedto
reach1.7millionmetrictonsby2015(Figure3).In2010,North
Americanbioplasticsproductionreached193,575metrictons,according
toEuropeanBioplastics.Todaythebioplasticsindustryrepresentsless
thanonepercentofglobalplasticsproduction,saysMelissaHockstad,
DirectoroftheSPIBioplasticsCouncil.Itsfastpacedandgrowingwith
anticipatedgrowthtoreachover20percentperyearthrough2015.
Lookingatthe2010globalbioplasticsproductionfigures,NorthAmerica
was26.7percentofthetotalglobalbioplasticsproductioncapacity.
Hockstadaddsthatby2015,NorthAmericashouldgrowto33percent
(Figure4).

TheFreedonia
Groupreported
similarstatisticsin
itsWorld
BioplasticsReport
releasedin
November2011.
Itnotesthat
demandfor
Figure3.Globalproductioncapacity bioplasticsin
ofbioplastics(Source:European NorthAmericawill
Bioplastics) growtoabout
267,000tonsin
2015.Biodegradableplasticsaccountedfornearly90
percentoftheglobalbioplasticsmarketin2010.BCC Figure4.Productioncapacityofbioplasticsin2015
Researchreportedtheglobalbiodegradablesmarket (byregion)(Source:EuropeanBioplastics)
reached932millionpoundsin2011andisexpectedto
increaseata22.5percentcompoundannualgrowthratetoreachnearly2.6billionpoundsin2016.

GrowthInCompostables
AccordingtoFreedonia,biodegradable/compostablestarchbasedresinsandPLAhavecapturednearly80percent
ofthemarketandbiodegradable/compostablepolyesterresinsaccountedfor9percentin2010(Figure5).Figure
6showsworldbioplasticsmarketdemandbyproductsectorsin2010.Compostablebags(currentlyabout40%)
shouldtripleindemandduetopendingregulationsandexpansionofthecompostinginfrastructure,although
therewillbecompetitionfrompaperbagsandreusableclothordurableplasticbagsinmajormarkets.Another
areaofgrowthisinfoodservicedisposables(currently22.5%),whichareprojectedtonearlydoubledemandfor
compostableresins.Lowerbioplasticcostsandproductavailability,growthinthecompostinginfrastructureand
consumerawarenesswillhelpdrivedemandforthisproductsector.(Industryanalyststendtousetheterms
biodegradableandcompostableasinterchangeableinmarketreports,oftenconfusingpeopleoutsideofthe
industry,especiallyconsumers.Part2ofthisarticleseriesaddressestheterminologyissue,includingtheFederal
TradeCommissionsdefinitions.)

Nearly40percentoftheglobalmaize(fieldcorn)
productionisgrownintheU.S.Sugar(dextrose)fromfield
cornisusedformanyindustrialpurposesandistheprimary
feedstockforproductionofbioplastics.Thelargevolume
feedstockusersareIngeopolylacticacid(PLA)from
NatureWorks(Cargill)andMaterBistarchbasedresinsfrom
Novamont,andtoacertainextentTellesMirel
polyhydroxyalkanoate(PHA).(Thejointventurebetween
MetabolixandADMwasterminatedinJanuary2012but
Metabolixplanstocontinuemanufacturingbiopolymers.)

NatureWorksislookingtodiversifyitsrawingredientsfor
production,particularlysugar.Otherplantbasedsourcesof
 Figure5.Worldbiodegradablesdemandbyresin sugar,includingsugarbeets,sugarcane,cassavaorwheat,
type(estimatedpercentages)(Source:Freedonia canbeusedasafeedstock.NatureWorkswillalsoconsider
WorldBioplasticsReport2011) makingitsIngeomaterialfromcellulosicrawmaterials,
agriculturalwastesandnonfoodplants,saysSteveDavies,
directorofcorporatecommunicationandpublicaffairswithNatureWorks.AccordingtoDavies,NatureWorks
principalmarketsarepackaging,durableproducts,foodserviceware,textilesforclothingandsoftgoods,and
personalcareitemssuchaswipes.Itsareasofgrowthareinpackagingandfoodservicefollowedbydurable
goodsandnonwovenfibersforwipes,diapersandfilters.

Fromitsfoundingin1989,Novamontwantedtointegrateagriculture,chemistryandfunctionality(like
compostabilityornewchemical/physicalproperties)ofitsMaterBipolymersintoawiderangeofindustrial
applications,includingcollectionoforganicsseparatedfrommunicipalsolidwasteandintendedforcomposting
(kitchenwastebags,shoppingbags),agriculturaluse(mulchfilmsandvariousotherdevices),packaging,
catering,clingfilmsandproducebags.Theseapplicationspresentopportunitiesforbioplasticstohelpreduce
contaminationoforganicwasteforthecompostingstream.Vegetableoils,starch,celluloseandlignocellulosescan
beusedasingredientsforNovamontsproductionprocess.

BASFhasbeenproducingbiodegradablecopolyesterecoflex()polymersthatarecurrentlyusedincompostable
trashbagsandsingleusedisposablepackaging.Duringmanufacturing,EcoflexcanbeusedsimilarlytoLDPEfor
productionoffilms,bagsorcoatings,andcanbeblendedwiththermoplasticstarchandotherbiodegradable
polymers.BASFsecovioisablendofecoflexandPLA(polylacticacid)forcompostablecateringitemslike
tablewareandclamshells.

Thereisaburstandanevolutionofnewbioplastics
companiesandproductionfacilitiesofferingawiderangeof
newmaterialsthathavemarketpotential.Afewofthese
newmarketentrieswilloffercompostables,including
DaniMerScientificandMeridian,sistercompaniesretro
fittinganexistingproductionplantinBainbridge,Georgia
forapilotoperationtoproduce30millionpounds/yearof
PHA.EcospansBioFlowisaproprietarybiopolymer,
blendedwithotherpetroleumfreeingredientsorwith
petroleumbasedingredientsforavarietyofproductsand
packaging.Ecospanworkswithclientsfromtheoutset,
startingwithapplicationdevelopmentandimplementation
ofanendoflifereuseandregrindstrategyinaclosedloop
modelthatkeepsmaterialresourcesinthevaluechainand Figure6.Worldbioplasticsbymarketdemand
outoflandfills.Anewcompany,LaurelBioCompositeLLC, (estimatedpercentages)(Source:FreedoniaWorld
ismanufacturingandmarketingabiobasedproductto BioplasticsReport2011)
replaceaportionoftraditionalplasticresinslikeHDPEina
varietyofapplications.

NonbiodegradableResins
Since2010,biobasedpolyethylene(bioPE)hasgainedrapidmarketacceptanceandisproducedinlargevolume.
ThisgrowthisexpectedtofuelbiobasedversionsofPP,polyvinylchloride(PVC)andpartialbiobasedpolyethylene
terephthalate(PET).Thesearenotbiodegradablebioplastics,howevertheyaremadefromrenewableresources,
primarilysugarcane.Theywillbeconsidereddropinreplacementsforpetroleumbasedplastics,astheproducts
areidenticalintheirchemicalstructureandphysicalproperties.Thesematerialshelpbrandownersincreasetheir
useofbiobasedcontenttosupportmarketingobjectives.ProductsmadefrombioPEmustberecycled,landfilled
orincineratedliketheirtraditionalplasticscounterparts.Thereforebeforegoingtomarket,brandownersand
distributorsshouldhaveanynewpackagingmaterialorpackagingdesigntestedatmaterialsrecoveryfacilities
(MRFs)forrecyclabilityinexistingsystems.

BraskemsbiobasedpolyethyleneplantinBrazilusessugarcaneasthefeedstock,aswillDowChemicalsplant
thatisexpectedtoopeninBrazilby2014.SeveralkeymarketsegmentshavedemonstratedthevalueofbioPE
includingconsumerpackagingmanufacturersProcter&Gamble,SwedishfoodpackagingcompanyTetraPakand
JapanesecosmeticscompanyShiseido.FutureproductionofcommodityplasticssuchasPP,PVCandPETfrom
biobasedsources,particularlyinBrazil,isalsoverylikelytousesugarcrops.Freedoniareportsthatglobal
productionofsugarcaneandsugarbeetswillincreasemorethantwopercentannuallytoreach2.2billionmetric
tonsin2015.
PartnershipsAlignSupplyChain
InJune,CocaCola,FordMotorCompany,H.J.HeinzCompany,NIKE,Inc.andProcter&Gambleannounced
formationofthePlantPETTechnologyCollaborative(PTC).Thesebigbrandswillworktogetherondevelopmentto
supportplantbasedPETbioPETthathasthesamechemicalstructureaspetroleumbasedPETandis
manufacturedlikePET.Fortheselargeconsumerbrandownersthatalreadyhavemajorproductsintendedforthe
recyclingstream,bioPETisimportanttotheirexistingoperationsandtheircorporatesustainabilityinitiatives.
BiobasedPETisrecyclablealongwithconventionalPET.BottlesmadefrombioPETcanberecycledthroughMRFs,
makingitaneasydropinreplacementforbrandownerstoadoptforexistingconsumerproductlines.

OnebigsplashisthePlantBottlepackagingtechnology,thefirstrecyclablebioPETplasticbeveragebottle
manufacturedwithupto30percentbiobasedPETmadefromsugarcane.TheCocaColaCompanymarketsthe
PlantBottleaspartiallymadefromplantswithalowerenvironmentalimpactwhencomparedtotraditionalPET
bottles.HeinzisnowlicensingthetechnologyfromCocaCola.PepsiCoisworkingonaplantbasedbottleusing
biomassfeedstockssuchasswitchgrass,pinebarkandcornhusks.Itisfocusedonpilotproductionofthenew
bottlein2012,withplansforfullscalecommercialization.Pepsisgoalistobroadenthefeedstockresourcesto
includeorangepeels,potatopeels,oathullsandotheragriculturalbyproductsfromitsfoodbusiness.

Industrystakeholdersareworkingtogetherwithresinmanufacturers,convertersanddistributorstoalignthe
supplychain.Thismutualundertakingwillenableabetterunderstandingofthepackagingneedsthatcan
translateovertoengineeringbioplasticmaterialpropertiesaroundthoseneeds.Thekeyistodesignwithendof
productlifestrategiesearlyintheprocessandtouseclearmarketingclaimsabouttheproperendoflifeforthe
packaging.

ProductAttempts
TheSunChips100percentcompostablebagmadewithIngeobiopolymerwasapackagingachievement.Thebag
wasdesignedtofullycompostinabout14weeksinahot,activecompostingpile.Whatfromtheoutsideappeared
asasimplesnackbag,wasacomplexmultilayerstructurethatrequiredbarrierpropertiestokeepmoistureand
oxygenout.Aspartofitssustainabilityendeavors,FritoLayworkedonalongdevelopmentscheduleto
implementuseofplantbasedrenewablematerials.Thiswasahugeandimportantrisk.TheSunChipsbagranup
againstaconsumerissuenoisecausedbystiffmaterialinamultilayerdesign.Butthenoisewasovercomewith
achangetoadhesivesusedbetweenthetwolayersofthebag.TheSunChipsbagwasalearningexperienceand
anopportunitytomakemodifications.Butitillustratestheunexpecteddifficultiesofnewproductdevelopment
andmarketacceptance.

Thesetypesofpackagingtrialsandexperimentsareneededtogrowmarketacceptanceofcompostable
packaging.Theindustryiscollaboratingtosolvepackagingproblems.Consumerpackagedgoodscompaniesnow
haveaknowledgebaseandunderstandingofbioplastics,whichisraisingthelevelofmarketacceptanceintomain
streamuse.Forexample,TargetincorporatedIngeobiopolymerinfilmbagsforitsinhouseArcherFarmsbrand
ofsnackchips.Thechipbagrepresentsthelatestgenerationofflexiblemultilayeredpackaging.

MakingInroads
Compostingandcompostableproductshavemadeinroadsprimarilyintheinstitutionalandcommercialsectorsin
theU.SThefoodserviceandcateringsectorisasignificantmarketforcewithmeasurablefactorsthatwillshape
bioplasticsproductiondevelopmentoverthenextseveralyears.Thegreatestimpactisonthesupplysideamong
resinproducers,distributorsandothersinthecompostablebioplasticsindustry.Agreaternumberofconverters
arebeginningtoworkwithcompostablepolymers.Distributorsoffoodservicepackagingnowhavefulllinesof
compostableitemsavailableingreaterquantityanddiversitytosupplytheincreasingfoodwasterecyclingand
zerowasteprograms.

Asfoodscrapsdiversioncontinuestogrow,opportunitieshavebecomemoreevidenttosupplierswhowerenot
earlyadopters,saysSteveMojo,executivedirectoroftheBiodegradableProductsInstitute(BPI).More
companiesareparticipatinginthismarket.Also,BPIcontinuestoseeimprovementsinpropertiesandprocessing,
whichhelptoimproveperformanceandinsomecaseslowercosts.Asmorediversionprogramsarecreated,
compostersarerealizingthatcompostablefoodserviceitemsareoneofthekeystocollectingandprocessing
morefoodscraps.Mojoaddsthatthenextwaveoffoodscrapsdiversionwillbedrivenbyresidentialcollection,
whereconsumersareactivelyinvolvedintheprocess.

Withfooddiversionprogramspositionedforgrowth,manufacturersareaddingcapacitytomeettheexpected
demandfromtheinstitutionalmarket,especiallycompostablefoodserviceitemsandcanliners.Manufacturersare
increasingthelevelofproductiontoensurethatavailabilityofcompostableproductsmatchesthemarketdemand.
Forexample,BASFhasincreasedproductionofecoflexfourfoldsince2010andcontinuestoincreaseecovioas
needed.

PartIIoftheBioplasticsIndustryReportwilladdressmarketingclaimsandhowcompostablesarebeing
marketedforcomposting.Italsowillreviewrecentdevelopmentsinrefiningindustrystandardsforcompostability
toreflectvariationsincompostingprocessesandtechnologies.

DebraDarbyisanindependentmarketingconsultantwithabackgroundinbioplasticsmarketing.

SourcesCited
EuropeanBioplasticswww.en.europeanbioplastics.org/multimedia
FreedoniaWorldBioplasticsReport2011www.freedoniagroup.com
BCCResearchwww.bccresearch.com/report/biodegradablepolymersmarketpls025d.html
BASFwww.basf.com/group/corporate/en/brand/ECOFLEX
ICISwww.icis.com/Articles/2011/02/28/9438198/dowstudiesbiobasedpropyleneroutes.html

ModifyingStandardsToMeetCompostingRealities
In2010,theUSCompostingCouncil(USCC)launchedtheCompostablePlasticsTaskforce(CPTF)toalignthe
valuechainandsupportthecompostingindustrywithaprotectedstreamofqualitymaterials(food,yard
trimmingsandcompostablematerials)withoutcontamination.TheCPTFidentifiedandprioritizedtopindustry
issuesthatchallengebothcompostersandcompostableplasticsproducers,actionsneededtoaddressthese
challenges,andhowbesttotakeadvantageofopportunitiespresented.TheCPTForganizedintothreeworking
groups:Standards&OperationalImpacts,Label&Identification,andLegislation&Enforcement.Throughthe
USCC,theextendedsupplychainisworkingtogetheronacompostablepathwaythatprovidesrealvalueanda
solution.TheStandards&OperationalImpactworkinggroupisfacilitatingchangestotheASTMD6400
standardspecificationforcompostableplasticsspecificallytocreateanewdisintegrationtestmethodthat
determinesthevisibledisappearanceofcompostablebagsandproduct.Thetestmethodishopedtobetter
replicateresultsofcompostingprocesses.Theworkinggroupisalsoadvocatingcompostableplasticsforuse
asafeedstockincompostforcertifiedorganicapplications,andisgatheringinformationtosupportpetitionsto
theNationalOrganicProgramfortheadditionofcompostablesubstratestothelistofacceptedfeedstocksfor
certifiedorganiccompost.(SeetheOrganicIndustryAndCompostablePlastics,AugustBioCycle2012)

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