bioplastic-2014

8/10/2019 Bioplastic-2014

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Bioplastics Production


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What are bioplastics?

Compostable plastics

-or-

Any plastics-made from

organisms (or organism by-

products)

Mixture of Acids that

could be made into

bioplastics


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Why Bioplastic?

Plastics are predominantly made from crude oil

Renewable resourcesare becoming a more viable andpromising alternative for the plastics industry

When plastics made from petroleum are burned, theyrelease the carbon dioxide contained in the petroleum intothe atmosphere, leading to global warming.

The use ofbioplasticsoffers significant advantages not onlyin an ecological sensebut alsoin aneconomical sense.


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Polystyrene: Coffee cups, Fast-food

Polyethylene:

HDPE: Milk containers

LDPE: Plastic bags, Packaging

Polyvinyl chloride: Piping, Meat wrap

Polyethylene terephthalate: Soda bottles


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Oil use: 100 billionpounds of plastics areproduced in NorthAmerica annually

Only 3% of these plasticsare recycled


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Importance

2003- North America

107 billion pounds of

synthetic plastics

produced from petroleum

Take >50 years to degrade

Improper disposal and

failure to recycleoverflowing landfills


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Making Bioplastics


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Enzymes are used to break starch in the plants down intoglucose, which is fermented and made into lactic acid.

This lactic acid is polymerized and converted into a plasticcalled polylactic acid, which can be used in themanufacture of products after being heated and shaped.

If something made of bioplastic is buried in the ground,microorganisms will break it down into carbon dioxide andwater.

StarchGlucoseLactic acidPoly lactic acid (PLA)

Bioplastics Production


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Goal of Bioplastic Production

1. To save resourcesby

either reducing the

production of standard

Polypropylene plastics

2. To save the

environmentby

making plasticsbiodegradable

Bioplastic

degradation speed


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Bioplastic production:

1. Using Soy-based bioplastics

2. Using Starch-based Bioplastics

3. Using Bacteria to make bioplastics

4. Poly-3-Hydroxyalkanoate

(PHA)/Hydroxybutyrate (PHB)


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Soy-based Bioplastics

One of the hottest sectionsin bioplastics researchtoday.

Pure Soy Bioplastic hasmany undesirable traits.

Mixtures of Soy with othersubstances are currently

being attempted.

Soy Protein


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Bacteria-based Bioplastics

Mixture of bacteria can create acids whenfermented.

The ratio of different acids is based on pH.The bacteria are fed glucose solution and

fermented.

The acids can be used to make bioplastics


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PHA/PHB

Easily biodegradable Easily processed

Very Expensive

Methylobacterium sp V49 is PHB producer


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Starch-based bioplastics

Make up about 50% of the current

bioplastic market

This is called thermo-plastical starch


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Use of Bioplastic

Bioplastics are already being used in

automobile interiorsand in cases for

consumer electronics.

Toyota Motor Corp. became the first

automaker in the world to use bioplastics inthe manufacture of auto parts.


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Toyota Motor is building a plant to undertake test

production of bioplastic at a factory in Japan, withproduction due to begin in August 2004.

The company plans to produce 1,000 tons of

bioplastic annually, which will be used not just in carparts but in many other plastic products as well.

Toyota also plans to use bioplastics in the

construction of the exhibitionpavilionsat the 2005World Exposition, Aichi, Japan, so that noconstruction waste is generated when the pavilionsare dismantled at the end of the event.

Used in Automobile


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Used in Electronic Devices

Mitsubishi Plastics has already succeeded in raisingthe heat-resistance and strength of polylactic acid by

combining it with other biodegradable plastics and

filler, and the result was used to make the plastic

casing of a new version of Sony Corp.'s Walkman

Mitsubishi Plastics had previously looked at

bioplastic as something that would mainly be used inthe manufacture of casings and wrappings.


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NEC Corp., is turning its attention to kenaf, a type of

fibrous plant native to tropical areas of Africa andAsia that is known to grow more than five meters in

just half a year.

A mixture ofpolylactic acid andkenaf fiberthat is20% fiber by weight allows for a plastic that is strongenough and heat resistant enough to be used inelectronic goods.

The goal is to begin using this new plastic in realproducts, such as computer cases.


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The use of bioplastics for shopping bagsis already

very common. After their initial use they can be reused as bagsfor organic waste and then be composted.

Trays and containersfor fruit, vegetables, eggs

and meat,bottles for soft drinks and dairyproducts are also already widely manufacturedfrom bioplastics.

Used in packaging


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Due to their specific characteristics, bioplastics areused as a basis for the production of sanitary

products.

These materials are breathable and allow water vaporto permeate, but at the same time they are waterproof.

Foils made of soft bioplastic are already used asdiaper foil, bed underlay, ladies sanitary products andas disposable gloves.

Used in Sanitary Products
http://www.bioplastics24.com/content/view/85/33/lang,en/http://www.bioplastics24.com/content/view/85/33/lang,en/


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Your foodcomes from

nature..Now so

does yourcontainer


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Applications
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Energy storage for bacteria

Physical properties of

polyethylene, polystyrene,

and synthetic polyesters

Polyhydroxyalkanoates

H

C CH2O C

CH3 O

Polyhydroxybutyrate

(PHB)

Polyhydroxyvalerate

(PHV)

H

C CH2O C

CH2 O

CH3


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Anaerobic

Environment

Abundant carbon

source

3-hydroxyacyl-CoA

polymerization


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Polyhydroxyalkanoates (PHAs)

Produced under conditions of:

Low limiting nutrients (P, S, N, O)

Excess carbon

2 different types:

Short-chain-length 3-5 Carbons

Medium-chain-length 6-14 Carbons

~250 different bacteria have been foundto produce some form of PHAs


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Polyhydroxybutyrate (PHB)

Example of short-chain-length PHA

Produced in activatedsludge

Found inAlcaligeneseutrophus

Accumulatedintracellularly asgranules (>80% cell dry

weight) Lee et al., 1996


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PHA Biosynthesis

Ojumu et al., 2004


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A carbon source (corn) is ground into a mash

and fed to PHA-forming bacteria

Glucose is extracted as the microbes fermentthe mash and store the energy as PHAs

The cells are washed and lysed

The PHAs are separated by centrifuge and

washed again

30% PHA by dry weight


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Recovery of PHAs from Cells

PHA producing microorganisms stainedwith Sudan black or Nile blue

Cells separated out by centrifugation orfiltration

PHA is recovered using solvents

(chloroform) to break cell wall & extractpolymer

Purification of polymer


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Organisms

Nostoc muscorum Synechocystis sp. PCC 6803 Synechococcus sp. MA1


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Plastics are resistant to biodegradation accumulating at the


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The Korean research center KAIST has announced thatthey have found a way to produce PLA using bio-engineered

Escherichia coli.

As of Jun 2010, NatureWorks was the primary producerof PLA (bioplastic) in the United States.

Plastics are resistant to biodegradation accumulating at therate of 25 million tonnes per year. Much disposed in landfillsites. Possibility of recycling plastics is limited andincineration yields toxic compounds


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Organisms

Ralstonia eutropha

Alcaligenes latus

Azotobacter vinelandii Paracoccus denitrificans

Recombinant E.coli

Bacillus subtilis
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The biosynthesis of PHA is usually caused

by certain deficiency conditions (e.g. lack

of macro elements such as phosphorus,

nitrogen, trace elements, or lack ofoxygen) and the excess supply of carbon

sources.


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Simplify Extraction

Secretion Mechanisms

1. Exploit natural secretion

mechanisms

2. Transform cell with plasmidcontaining lysis gene


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High start-up costs (3-5 x

higher than petroleum-basedplastics)

Labor intensive processing

High energy demands

Challenges Facing Bioplastics


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