Bio-based PLA films with additives for rigid packaging development

Overview

Our innovative solution utilizes bio-based polylactic acid (PLA) derived from locally upcycled whey to create next-generation rigid food packaging. By integrating advanced bio-composites that combine PLA with tailored plasticizers, starch, and natural fique fibers, we produce rigid sheets that offer enhanced stiffness, improved impact resistance, and optimized thermoformability. This technology is designed for applications in extrusion, thermoforming, and injection molding, making it ideal for the production of high-performance trays and containers with substantial renewable content. This sustainable approach significantly reduces the dependency on imported petrochemical resins while providing a robust packaging solution for high-acid ready-to-eat meals.

Technical specifications

• Bio-based PLA: High-molecular-weight PLA derived from upcycled cheese whey.
• Material composition: Incorporation of plasticizers, starch, and natural fique fibers to enhance performance.
• Thermal resistance: Capable of withstanding thermal treatments between 90-130 °C.
• Barrier properties: Improved oxygen and moisture barrier performance, ensuring extended shelf life without compromising food safety.
• Applications: Suitable for extrusion, thermoforming, and injection molding.
• Performance: Enhanced stiffness, seal integrity, and dimensional stability.

Technology readiness level

This technology is currently at TRL 6, having been validated in relevant environments. Future plans include a 12–18 month research program to further optimize material properties and validate processing techniques, with a focus on regulatory compliance and industrial scalability.