Recipient Organization
METABOLIX, INC.
21 ERIE STREET
CAMBRIDGE,MA 02139-4260
Performing Department
(N/A)
Non Technical Summary
The widespread use of synthetic plastics has increased concerns over their adverse environmental impacts, and dramatic fluctuations in the cost and availability of petrochemical sources for plastic production creates the need for renewable, environmentally-friendly plastics derived from agricultural sources. Blow molded products are used widely in packaging, and are a major component of the plastics manufacturing industry that are suitable for replacement by biobased materials. This project will demonstrate the use of Polyhydroxyalkanoates (PHAs), a family of bioplastics made by the biological conversion of agricultural feedstocks, in commercial-scale blow molding manufacturing operations. Advances in PHA formulation and processing technology developed in Phase 1 of the project demonstrated the feasibility of blow molding PHAs at the lab-scale. In this program, PHA formulations will be improved with the necessary melt strength and crystallization behavior for blow molding operations using existing equipment at current production fficiencies, while providing the key physical properties needed in the blow molded part. Once satisfactory formulations are developed, pilot blow molding trials will be conducted to confirm proper rheological behavior of the PHA formulations and physical properties of the molded part. Metabolix will then demonstrate blow molding on commercial scale equipment running at typical manufacturing speeds.
Animal Health Component
100%
Research Effort Categories
Basic
(N/A)
Applied
100%
Developmental
(N/A)
Goals / Objectives
The specific technical objectives of Phase 2 of this project are to develop biobased PHA resin formulations with processing properties suitable for large-scale blow molding operations, demonstrate blow molding at commercial scale, map the physical properties of the blow molded product, and optimize blow molding cycle times to that of commercial production specifications. Metabolix will use a combination of high molecular weight biobased PHAs, in conjunction with reactive extrusion processes, to create blends of branched and linear PHAs with the required rheological properties and melt strength for blow molding operations on commercial scale equipment. These formulations will be further improved in conjunction with blow molding process optimization to achieve commercial line speeds and meet full end-use container physical properties. Success in this project will open up a large segment of the current thermoplastics market to biobased PHA products.
Project Methods
The following tasks are critical to the successful development of PHA resin formulations suitable for blow molding and the production of blow molded products from biobased PHA polymers: 1. Synthesis and molecular characterization of branched PHAs; 2. Production and characterization of blends of linear and branched PHAs of varying molecular weights and compositions; 3. Conduct lab-scale blow molding, measure and map physical properties of item; 4. Conduct commercial-scale blow molding, measure and map physical properties of item; 5. Optimize formulation to meet commercial scale blow molding times. Results obtained from Phase 1 of the program will form the basis for moving forward with Task 1 and 2 to develop formulations that have the desired elastic and viscous properties at the preferred processing conditions for PHAs. Lab-scale blow molding operations similar to that conducted in the Phase 1 project will be conducted to demonstrate improved melt strength and required rheological behavior needed for larger scale blow molding operations. Physical properties of the blow molded object will be measured and mapped as a basis for comparison with a standard PET blow molded object. Once a formulation(s) is identified that has the required combination of melt strength and physical properties, blow molding operations will be conducted on commercial-scale blow molding equipment. Metabolix has worked with several plastics converters with commercial blow molding equipment available for testing these formulations. Once commercial scale objects have been blow molded, the physical properties will be measured and mapped, then compared with PET blow molded items to ensure equivalent product characteristics. The final task will be to optimize the blow molding formulation to increase blow molding production to that obtained by commercial resins. The work proposed in this project will use PHA polymer produced by Metabolix's microbial fermentation process. This material, estimated to be approximately 5000 lbs, will be provided by the Metabolix-ADM commercial production facility scheduled to begin operation in late-2009.