Production-scale trials demonstrate stable film processing, formulation flexibility and a path to eliminating a separate compounding step
Once again, this major development success is the result of a joint team effort, this time consisting of BioLogiQ Inc. as the developer of specialized thermoplastic starch grades and compounds thereof – brand name NuPlastiQ™ – and Reifenhauser Group, Blown Film Unit, the equipment manufacturer of high-end blown film lines.
The trials were conducted on a Reifenhauser EVO Fusion 5-layer blown film line and were designed to determine whether individually fed components could produce film comparable to material made from a pre-compounded BioLogiQ blend.
The trials successfully replicated the film results of the benchmark compounded formulation while demonstrating stable processing at production-relevant throughput. The work also showed that direct feeding can give film converters greater control over formulation, compatibilizer loading and resin selection – while potentially eliminating the cost and logistics associated with a separate compounding step.
Successful production-scale demonstration
This trial used the EVO Fusion line in its existing configuration; no equipment modifications were made. Only process parameters were adjusted. The line utilized a twin-screw extruder for the core layer and single-screw extruders for the outer layers.
For the test series having a biobased content of >26% we analyzed key film parameters. We compared 3 film samples.
- the control film (the core layer consists of pre-compounded bioblend and an mLLDPE in the ratio of 80/20),
- the identical composition of the control film, but fed directly in the extruder as single components
- single components, but reduced compatibilizer
Why dry blending matters to film converters
Eliminates a separate compounding step
In the conventional approach described in the trial report, NuPlastiQ™, LLDPE and compatibilizer are first compounded into a finished blend before that material is delivered to the film converter. Direct blending shifts that mixing step to the blown-film line. For converters with suitable equipment and process controls, this can remove a discrete conversion step and its associated processing, transportation and inventory costs.
Provides greater formulation flexibility
Direct feeding allows a film producer to adjust the NuPlastiQ™, LLDPE and compatibilizer ratios at the line instead of relying on a fixed pre-compounded formulation. That flexibility can make it easier to tune formulations for film performance, the LLDPE grade already in use, changing customer requirements and different production campaigns.
Can reduce inventory complexity
Rather than stocking multiple pre-compounded grades, a converter may be able to manage a smaller set of individual raw materials and create the required formulation during production. This can improve sourcing flexibility and reduce dependence on the availability and lead time of a specific finished compound.
Technical considerations
The trials also identified operating boundaries that will matter in commercial implementation. At the highest tested throughput, the extruder temperature profile increased to approximately 200°C, which the trial report identified as approaching the temperature range where NuPlastiQ™ degradation can begin. The results therefore support continued optimization of throughput, temperature control, formulation and final film performance for each production line and application.
The trial work further showed that reducing compatibilizer is possible, but the tested reduction increased haze and reduced manual tear strength. This reinforces the need to optimize the formulation for the required end-use properties rather than treating dry blending as a one-formulation-fits-all approach.
Detailed report and where to get BioLogiQ resins
A more detailed report is available upon request. Please contact Frank Juergens, Director of Strategic Business Development, Europe, or BiologiQ (website form): https://www.biologiq.com/contact/ .
For requests in BioLogiQ’s NuPlastiQ™ or compounds in Europe, please contact our distribution partner Plastrans Technologies GmbH in Linz (Austria).
Next steps
BioLogiQ views the successful dry-blending demonstration as a platform for continued development with film converters and equipment partners. Future work can focus on optimizing recipes for specific LLDPE grades, production rates, film structures and performance requirements, while evaluating the commercial savings available from eliminating pre-compounding.
Companies interested in evaluating NuPlastiQ™ in blown-film applications are encouraged to work with BioLogiQ’s technical team to define the appropriate material combination and trial conditions for their equipment and target application.
About BioLogiQ
BioLogiQ supplies NuPlastiQ™ thermoplastic starch materials and related blends for film and other polymer applications. NuPlastiQ™ is designed for use with conventional polymers to incorporate biobased content and enable new material formulations. www.biologiq.com
About Reifenhäuser
Founded in 1911, the Reifenhäuser Group is a leading provider of innovative technologies and components for plastic extrusion. Through our highly specialized business units, we deliver advanced solutions that help customers around the world maximize performance, efficiency, and product quality. With the expertise of more than 1,500 employees, we enable the production of blown films, cast films, sheets, and nonwovens. In addition, we provide premium components for the extrusion industry, supporting manufacturers in meeting evolving market demands, achieving long-term success, and advancing sustainability. www.reifenhauser.com