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56 bioplastics MAGAZINE [04/23] Vol. 18 Basics Overcoming challenges in PHA injection moulding The plastics industry is increasingly aware of the need to reduce the environmental impact of traditional plastics and embrace more eco-friendly alternatives. Biodegradable biopolymers, like PHAs, offer a promising solution, but their unique properties pose challenges in the injection moulding process. This article shall explore four common challenges and how to overcome them. Thermal Degradation: PHAs have a limited processing window between their thermal degradation and melting temperatures, making them sensitive to temperature and residence time. To address this, fine-tune the control (PID) settings for the extruder and mould heating controller and reduce idle time to a minimum. Additionally, be mindful of shear forces during transportation from the extruder to the mould cavity by using mould constructions that lower shear. Employ a tuned hot runner for successful material transfer. Having experienced operators is crucial to identifying and addressing visual degradation or defects promptly. Melt Flow and Crystallinity Optimising melt parameters is vital for creating highquality PHA products. Higher melt flow helps fill voids in the mould cavity, but achieving the right balance of crystallinity is essential. Some applications require partial crystallisation in the mould, which necessitates higher mould temperatures. However, excessive crystallinity can increase brittleness. Finding the optimal strength and flexibility for the finished part will involve trial and error based on the specific resin. Consider using non-stick coatings on mould cavities to avoid parts sticking to the mould. Drying Process Proper drying of PHAs is crucial since they can hold up to 1 % moisture when saturated, leading to further degradation. The ideal processing moisture content is below 500 ppm. Ensure to dry the resin above 70°C for at least four hours, and use a calibrated moisture analyser to confirm it’s within the processing window. Purging Adequate purging is vital during PHA processing. When the material sits idle in the barrel or hot runner, degraded material can build up. Choose an appropriate purge resin with a melt flow and melting temperature that closely match the PHA to cleanse degraded material and carbon deposits. Skilled operators who can recognise these limitations will minimise downtime and reduce waste. Bioplastics, especially PHAs, hold great promise for a sustainable future. It can be very tempting to mix PHA’s with other biopolymers or even traditional polymers to broaden processing windows. However, there is a great risk to compromising their natural ability to be fully biodegradable or even compostable. Generating or shedding toxic microplastic that can harm the environment needs to be considered. And the author strongly discourages the temptation to produce products aimed at greenwashing exercises. As more companies and consumers prioritise eco-friendly products, PHAs and other bioplastics will become increasingly important. To stay ahead of the curve, manufacturers should embrace these materials and tackle their unique challenges. Beyond Plastic takes pride in its 75+ years of combined experience in various injection moulding processes. And they are dedicated to creating a more sustainable future by offering custom compounded alternatives to conventional plastics using PHA. www.beyondplastic.com By: Fred Pinczuk, CTO Beyond Plastic Commerce, CA, USA
ioplastics MAGAZINE [04/23] Vol. 18 57 Basics book on Bioplastics Now available in 6 languages ORDER NOW www.bioplasticsmagazine.com/en/books email: books@bioplasticsmagazine.com phone: +49 2161 6884463 ADVANCED RECYCLING Conference 2023 28–29 November Cologne (Germany) Hybrid Event advanced-recycling.eu Diversity of Advanced Recycling of Plastic Waste All you want to know about advanced recycling technologies and renewable chemicals, building-blocks, monomers, and polymers based on recycling CALL FOR ABSTRACTS Submit your Abstracts until 30 August 2023 Contact Dr Lars Krause Program lars.krause@nova-institut.de TOPICS OF THE CONFERENCE • Markets and Policy • Circular Economy and Ecology of Plastics • Physical Recycling • Biochemical Recycling • Chemical Recycling • Thermochemical Recycling • Other Advanced Recycling Technologies • Carbon Capture and Utilisation (CCU) • Upgrading, Pre- and Post-treatment Technologies Dominik Vogt Conference Manager dominik.vogt@nova-institut.de Organiser
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