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Bio-based Additives to Improve the
Performance & Processing of Biopolymers
Nathan Noyes
Global Business Development Manager
nathan.noyes@cargill.com
Sustainable Plastics
Los Angeles, 2023
© 2022 Cargill, Incorporated. All rights reserved.
Agenda
2
Introduction to Cargill
Polymer Additives
Challenges of processing
biopolymers
Specialty additives for
biopolymers
Additives in Biopolymers - 2023
© 2022 Cargill, Incorporated. All rights reserved.
Why Do We Need Additives in Biopolymers ?
3
Nowadays, most common polymers can be biobased, therefore the need for processing aid, mold
release, slip & anti-scratch performance, as well as anti-static and anti-fog effect is the same as in
fossil-based polymers.
Biopolymers such as PLA, exhibit high surface energy & low
shrinkage which can cause problems during film & sheet
extrusion and injection molding
Polyester-based biopolymers are used in engineering
applications
Polyester-based biopolymers are used in packaging
applications, where good aesthetics are required
Mold release & slip effect
Anti-scratch effect
Anti-static effect
Many biopolymers are transparent and are therefore used in
food applications Anti-fog effect
Additives in Biopolymers - 2023
How is Cargill Bioindustrial positioned to help?
4
Access To
Renewable
Crops
Portfolio
Approach
Partnerships
Application
Expertise
Feedstock
Conversion
Technologies
Additives in Biopolymers - 2023
© 2022 Cargill, Incorporated. All rights reserved.
What Additives Can Cargill Offer for Biopolymers?
Slip, anti-block &
anti-scratch
Migrating anti-static
& anti-fog
Processing aid Permanent anti-static
Ionphase™
Atmer™ 103 Atmer
Optislip
IncroMax™ 100
6
• Bio-based options available
• Food contact approval*
• Supplied as 100% active
• Incorporated either via compounding with the resin or dosed via masterbatch
• Generally used at dosages <1%, not impacting polymer compostibility, if applicable
Additives in Biopolymers - 2023
* Food contact approval varies per product per region
© 2022 Cargill, Incorporated. All rights reserved.
Bio-based additives, including carbon negative options
• We have calculated the Life Cycle Assessments (LCA) of our
additives to determine the carbon footprint
• Our LCA calculations are possible due to our back integrated
raw material supply and supply chain transparency
• Our slip additives have a negative carbon footprint – we
remove more CO2 from the atmosphere than we emit during
production
• These excellent results are possible due to bio-based raw
materials, and sustainable transport, green energy choices
and efficient manufacturing processes
• Results are externally verified
Additives in Biopolymers - 2023 7
© 2022 Cargill, Incorporated. All rights reserved.
High Performance Slip, Anti-block & Anti-scratch Additives
8
Additives in Biopolymers - 2023
Product Effect Chemistry Polymer Renewable Carbon
Atmer 103 Processing aid Ester PLA & PLA blends 100%
Optislip ER Slip Amide Bio PE & PP, PLA, PBAT,
PHA, PHBH
100%
Optislip BR Anti-block Amide Bio PE & PP, PLA, PBAT,
PHBH
100%
Optislip SRV Slip Amide Bio PE & PP, PLA, PBAT 94%
IncroMax 100 Slip & anti-scratch Ester PLA, PBAT, PHA 100%
Range of products suitable in injection molding and film extrusion applications
© 2022 Cargill, Incorporated. All rights reserved.
Can be optimized for internal or external lubrication
Migration mechanism of organic polymer additives
Additives in Biopolymers - 2023
Additive is uniformly
distributed in the polymer
immediately after
extrusion or injection
molding
As the polymer cools,
additive migrates to
the outer surface and
forms a partial layer,
providing the desired
effect
At equilibrium, complete
layers of additive form
on the surface. Effect is
maximized
9
© 2022 Cargill, Incorporated. All rights reserved.
Processing Aid Effect of Atmer 103 on PLA
10
Additives in Biopolymers - 2023
Atmer 103 is used to improve
processability of the polymer
during injection molding and film
extrusion.
It performs well in a variety of
biopolymers including PLA & PLA
blends.
0
20
40
60
80
100
120
0 5 10 15
Injection
pressure
(bar)
Screw position (mm)
Blank PLA PLA+1% Atmer103
© 2022 Cargill, Incorporated. All rights reserved.
Effect of IncroMax 100 on CoF of PLA Films
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
Blank 0.5% IncroMax100
Dynamic
CoF
Dynamic CoF of 50 μm cast extruded PLA films
11
Additives in Biopolymers - 2023
When 0.5% of IncroMax 100
is used in different polymers,
the dynamic coefficient of
friction is significantly
reduced, leading to easier
processing of the polymer.
© 2022 Cargill, Incorporated. All rights reserved.
Effect of IncroMax 100 on CoF of PLA based Films
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
Blank 0.5% IncroMax 100
Dynamic
CoF
Dynamic CoF of 250 μm cast extruded Floreon PLA based films*
* PLA based films supplied by Floreon™
12
Additives in Biopolymers - 2023
Low coefficient of friction
value achieved with
IncroMax™ 100 in a PLA
based blend film.
© 2022 Cargill, Incorporated. All rights reserved.
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
Blank PLA * PLA/PBAT + 0.5% Optislip ER
Dynamic
CoF
Dynamic CoF of 50 μm blown extruded PLA/PBAT films
Effect of Optislip ER on CoF of PLA/PBAT Films
* Blank CoF value for cast extruded PLA used as reference. With our specific equipment, we could not extrude blank PLA/PBAT
13
Additives in Biopolymers - 2023
Extremely low coefficient of
friction value achieved with
just 0.5% of Optislip ER in
PLA/PBAT films, providing
excellent slip performance for
easier processing.
© 2022 Cargill, Incorporated. All rights reserved.
Effect of Additives on CoF of PLA/PHA Films
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
Blank 0.35% Optislip ER 0.5% IncroMax
100
1% Optislip ER,
0.5% Optislip BR
Dynamic
CoF
Dynamic CoF of 50 μm cast extruded PLA/PHA films
14
Additives in Biopolymers - 2023
Low coefficient of friction value
achieved with blends of
Optislip ER & Optislip BR, as well
as with IncroMax 100, offering
excellent slip performance for
easier processing.
© 2022 Cargill, Incorporated. All rights reserved.
Effect of IncroMax 100 on Scratch Resistance of Injection
Molded PLA Plaques
15
Control
PLA + 0.5% IncroMax 100
0.68mm
15N → 1N
15N 1N
9N
Additives in Biopolymers - 2023
• Less damage caused by scratches when using
IncroMax 100, especially up to 9N load
• Scratches less visible due to lower contrast between
scratches and background
Erichsen Scratch Hardness Tester 430 PI
Scratch tip Ø = 1mm
Scratch load = 1 – 15N, 1N increment
Scratch speed = 100mm/s
Conditions = 23 ⁰C and 50% relative humidity
© 2022 Cargill, Incorporated. All rights reserved.
IncroMax 100 and Optislip ER do not affect the clarity of PLA at doses up to 0.5%
Optical Properties of Additives in Injection molded PLA Plaques
• Colour can be defined by L*, a*, b*, c* and h*
Haze
L: Luminance/lightness
a: Green-red
b: Blue-yellow
c: Chroma
h: Hue
Data name Haze L* a* b* c* h*
PLA control 1.83 95.64 -0.30 2.04 2.06 98.28
PLA + 0.5% IncroMax 100 1.52 95.96 -0.32 1.90 1.93 99.48
PLA + 0.5% Optislip ER 0.62 95.73 -0.32 2.11 2.13 98.74
16
Additives in Biopolymers - 2023
CONFIDENTIAL. This document contains Cargill Confidential information. Disclosure, use or reproduction outside Cargill or inside
Cargill, to or by those who do not have a need to know is prohibited. © 2022 Cargill, Incorporated. All rights reserved.
Introduction to
Migrating Anti-static
& Anti-fog Additives
© 2022 Cargill, Incorporated. All rights reserved.
Internally added anti-fog and anti-static additives into biopolymers
18
Additives in Biopolymers - 2023
Product Effect Chemistry Polymer Application
ATMER 190 Anti-static Alkyl sulphonate Bio PE & PP, PLA,
PBAT, PHA, PHBH
Food packaging
Atmer 129 Anti-static Glycerol Ester Bio PE & PP Food packaging
Atmer 110 Anti-fog Sorbitan Ester PBAT based blends Food packaging
Atmer 185 Anti-fog Glycerol Ester Bio PE & PP Agricultural films
Atmer 1440 Anti-fog Glycerol Ester Bio PE & PP Food packaging
Range of products suitable in injection molding and film extrusion applications
© 2022 Cargill, Incorporated. All rights reserved.
Anti-static effect of Atmer 190
Material
Charge decay
half-life (s)
Blank PLA > 40
PLA + 2% Atmer 190 3
PLA + 3% Atmer 190 3
Floreon PLA blend - blank > 40
Floreon PLA blend + 2% Atmer 190 1
19
Additives in Biopolymers - 2023
7.E+14
2.E+11
3.E+10
2.E+14
1.E+11
1.E+08
1.E+10
1.E+12
1.E+14
1.E+16
Blank PLA 2% Atmer 190 3% Atmer 190 Blank Floreon
PLA blend
2% Atmer 190
Surface
Resistivity
(Ω)
Atmer 190 decreases the time it takes to
dissipate 50% of the initial charge, compared
to blank PLA and blank Floreon PLA blends
• Atmer 190 can be added to polymers as a masterbatch, during compounding or directly in extrusion or injection molding
• Atmer 190 is recommended at the following doses:
- PLA: Up to 3%
- Floreon PLA blends: Below 3%
* PLA based films supplied by Floreon™
© 2022 Cargill, Incorporated. All rights reserved.
Effect of Atmer 190 on Mechanical Properties
• Tests conducted using ASTM D638
20
Additives in Biopolymers - 2023
2% of Atmer 190 has no major effect on tensile properties of either PLA or PLA blends*
* PLA based films supplied by Floreon™
0
0.5
1
1.5
2
2.5
Blank PLA 2% Atmer
190
Blank
Floreon
PLA blend
2%
Atmer190
Young's
modulus,
E
(GPa)
0
10
20
30
40
50
60
70
Blank PLA 2% Atmer
190
Blank
Floreon
PLA blend
2%
Atmer190
Tensile
strength,
UTS
(MPa)
0
50
100
150
200
250
300
350
400
450
Blank PLA 2% Atmer
190
Blank
Floreon
PLA blend
2%
Atmer190
Strain
at
break,
ε
(%)
© 2022 Cargill, Incorporated. All rights reserved. 21
Additives in Biopolymers - 2023
Blank
PLA
PLA
+ 2% Atmer 190
PLA
+ 3% Atmer 190
Floreon PLA
blend - blank
Floreon PLA
blend
+2% Atmer 190
Effect of Atmer 190 on Optical Properties
Atmer 190 has no effect on either the haze or color of PLA and Floreon PLA blends*
* PLA based films supplied by Floreon™
Data name Haze L a b c h
Blank PLA 0.2 97.1 -0.02 0.27 0.27 93.72
PLA + 2% Atmer 190 0.22 97.12 -0.01 0.25 0.25 93.23
PLA + 3% Atmer 190 0.86 96.99 -0.02 0.28 0.28 93.41
Floreon PLA blend –
blank
n/a 66.82 -0.84 -4.38 n/a n/a
Floreon PLA blend
+2%Atmer 190
n/a 65.48 -0.8 -4.29 n/a n/a
© 2022 Cargill, Incorporated. All rights reserved.
Permanent Anti-Static Additives
22
Additives in Biopolymers - 2023
• Ionphase Inherently Dissipative Polymers (IDP), also known as ion conductive polymers, reduce the resistivity of the
polymer providing control and safety for static related issues
• These additives offer an immediate and permanent effect, are humidity independent and offer good compatibility with host
polymers with minimal change to the properties of the host polymer
• Ionphase additives are suitable for compounding, extrusion or injection molding, and generally can be recycled
• Ionphase is suitable for use in polymers including:
– PLA & PLA blends
– PBS
• Recommended grade:
– Ionphase trSTAT
BIO-BASED ADDITIVES TO IMPROVE THE PERFORMANCE & PROCESSING OF BIOPOLYMERS

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BIO-BASED ADDITIVES TO IMPROVE THE PERFORMANCE & PROCESSING OF BIOPOLYMERS

  • 1. Bio-based Additives to Improve the Performance & Processing of Biopolymers Nathan Noyes Global Business Development Manager nathan.noyes@cargill.com Sustainable Plastics Los Angeles, 2023
  • 2. © 2022 Cargill, Incorporated. All rights reserved. Agenda 2 Introduction to Cargill Polymer Additives Challenges of processing biopolymers Specialty additives for biopolymers Additives in Biopolymers - 2023
  • 3. © 2022 Cargill, Incorporated. All rights reserved. Why Do We Need Additives in Biopolymers ? 3 Nowadays, most common polymers can be biobased, therefore the need for processing aid, mold release, slip & anti-scratch performance, as well as anti-static and anti-fog effect is the same as in fossil-based polymers. Biopolymers such as PLA, exhibit high surface energy & low shrinkage which can cause problems during film & sheet extrusion and injection molding Polyester-based biopolymers are used in engineering applications Polyester-based biopolymers are used in packaging applications, where good aesthetics are required Mold release & slip effect Anti-scratch effect Anti-static effect Many biopolymers are transparent and are therefore used in food applications Anti-fog effect Additives in Biopolymers - 2023
  • 4. How is Cargill Bioindustrial positioned to help? 4 Access To Renewable Crops Portfolio Approach Partnerships Application Expertise Feedstock Conversion Technologies Additives in Biopolymers - 2023
  • 5.
  • 6. © 2022 Cargill, Incorporated. All rights reserved. What Additives Can Cargill Offer for Biopolymers? Slip, anti-block & anti-scratch Migrating anti-static & anti-fog Processing aid Permanent anti-static Ionphase™ Atmer™ 103 Atmer Optislip IncroMax™ 100 6 • Bio-based options available • Food contact approval* • Supplied as 100% active • Incorporated either via compounding with the resin or dosed via masterbatch • Generally used at dosages <1%, not impacting polymer compostibility, if applicable Additives in Biopolymers - 2023 * Food contact approval varies per product per region
  • 7. © 2022 Cargill, Incorporated. All rights reserved. Bio-based additives, including carbon negative options • We have calculated the Life Cycle Assessments (LCA) of our additives to determine the carbon footprint • Our LCA calculations are possible due to our back integrated raw material supply and supply chain transparency • Our slip additives have a negative carbon footprint – we remove more CO2 from the atmosphere than we emit during production • These excellent results are possible due to bio-based raw materials, and sustainable transport, green energy choices and efficient manufacturing processes • Results are externally verified Additives in Biopolymers - 2023 7
  • 8. © 2022 Cargill, Incorporated. All rights reserved. High Performance Slip, Anti-block & Anti-scratch Additives 8 Additives in Biopolymers - 2023 Product Effect Chemistry Polymer Renewable Carbon Atmer 103 Processing aid Ester PLA & PLA blends 100% Optislip ER Slip Amide Bio PE & PP, PLA, PBAT, PHA, PHBH 100% Optislip BR Anti-block Amide Bio PE & PP, PLA, PBAT, PHBH 100% Optislip SRV Slip Amide Bio PE & PP, PLA, PBAT 94% IncroMax 100 Slip & anti-scratch Ester PLA, PBAT, PHA 100% Range of products suitable in injection molding and film extrusion applications
  • 9. © 2022 Cargill, Incorporated. All rights reserved. Can be optimized for internal or external lubrication Migration mechanism of organic polymer additives Additives in Biopolymers - 2023 Additive is uniformly distributed in the polymer immediately after extrusion or injection molding As the polymer cools, additive migrates to the outer surface and forms a partial layer, providing the desired effect At equilibrium, complete layers of additive form on the surface. Effect is maximized 9
  • 10. © 2022 Cargill, Incorporated. All rights reserved. Processing Aid Effect of Atmer 103 on PLA 10 Additives in Biopolymers - 2023 Atmer 103 is used to improve processability of the polymer during injection molding and film extrusion. It performs well in a variety of biopolymers including PLA & PLA blends. 0 20 40 60 80 100 120 0 5 10 15 Injection pressure (bar) Screw position (mm) Blank PLA PLA+1% Atmer103
  • 11. © 2022 Cargill, Incorporated. All rights reserved. Effect of IncroMax 100 on CoF of PLA Films 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 Blank 0.5% IncroMax100 Dynamic CoF Dynamic CoF of 50 μm cast extruded PLA films 11 Additives in Biopolymers - 2023 When 0.5% of IncroMax 100 is used in different polymers, the dynamic coefficient of friction is significantly reduced, leading to easier processing of the polymer.
  • 12. © 2022 Cargill, Incorporated. All rights reserved. Effect of IncroMax 100 on CoF of PLA based Films 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 Blank 0.5% IncroMax 100 Dynamic CoF Dynamic CoF of 250 μm cast extruded Floreon PLA based films* * PLA based films supplied by Floreon™ 12 Additives in Biopolymers - 2023 Low coefficient of friction value achieved with IncroMax™ 100 in a PLA based blend film.
  • 13. © 2022 Cargill, Incorporated. All rights reserved. 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 Blank PLA * PLA/PBAT + 0.5% Optislip ER Dynamic CoF Dynamic CoF of 50 μm blown extruded PLA/PBAT films Effect of Optislip ER on CoF of PLA/PBAT Films * Blank CoF value for cast extruded PLA used as reference. With our specific equipment, we could not extrude blank PLA/PBAT 13 Additives in Biopolymers - 2023 Extremely low coefficient of friction value achieved with just 0.5% of Optislip ER in PLA/PBAT films, providing excellent slip performance for easier processing.
  • 14. © 2022 Cargill, Incorporated. All rights reserved. Effect of Additives on CoF of PLA/PHA Films 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 Blank 0.35% Optislip ER 0.5% IncroMax 100 1% Optislip ER, 0.5% Optislip BR Dynamic CoF Dynamic CoF of 50 μm cast extruded PLA/PHA films 14 Additives in Biopolymers - 2023 Low coefficient of friction value achieved with blends of Optislip ER & Optislip BR, as well as with IncroMax 100, offering excellent slip performance for easier processing.
  • 15. © 2022 Cargill, Incorporated. All rights reserved. Effect of IncroMax 100 on Scratch Resistance of Injection Molded PLA Plaques 15 Control PLA + 0.5% IncroMax 100 0.68mm 15N → 1N 15N 1N 9N Additives in Biopolymers - 2023 • Less damage caused by scratches when using IncroMax 100, especially up to 9N load • Scratches less visible due to lower contrast between scratches and background Erichsen Scratch Hardness Tester 430 PI Scratch tip Ø = 1mm Scratch load = 1 – 15N, 1N increment Scratch speed = 100mm/s Conditions = 23 ⁰C and 50% relative humidity
  • 16. © 2022 Cargill, Incorporated. All rights reserved. IncroMax 100 and Optislip ER do not affect the clarity of PLA at doses up to 0.5% Optical Properties of Additives in Injection molded PLA Plaques • Colour can be defined by L*, a*, b*, c* and h* Haze L: Luminance/lightness a: Green-red b: Blue-yellow c: Chroma h: Hue Data name Haze L* a* b* c* h* PLA control 1.83 95.64 -0.30 2.04 2.06 98.28 PLA + 0.5% IncroMax 100 1.52 95.96 -0.32 1.90 1.93 99.48 PLA + 0.5% Optislip ER 0.62 95.73 -0.32 2.11 2.13 98.74 16 Additives in Biopolymers - 2023
  • 17. CONFIDENTIAL. This document contains Cargill Confidential information. Disclosure, use or reproduction outside Cargill or inside Cargill, to or by those who do not have a need to know is prohibited. © 2022 Cargill, Incorporated. All rights reserved. Introduction to Migrating Anti-static & Anti-fog Additives
  • 18. © 2022 Cargill, Incorporated. All rights reserved. Internally added anti-fog and anti-static additives into biopolymers 18 Additives in Biopolymers - 2023 Product Effect Chemistry Polymer Application ATMER 190 Anti-static Alkyl sulphonate Bio PE & PP, PLA, PBAT, PHA, PHBH Food packaging Atmer 129 Anti-static Glycerol Ester Bio PE & PP Food packaging Atmer 110 Anti-fog Sorbitan Ester PBAT based blends Food packaging Atmer 185 Anti-fog Glycerol Ester Bio PE & PP Agricultural films Atmer 1440 Anti-fog Glycerol Ester Bio PE & PP Food packaging Range of products suitable in injection molding and film extrusion applications
  • 19. © 2022 Cargill, Incorporated. All rights reserved. Anti-static effect of Atmer 190 Material Charge decay half-life (s) Blank PLA > 40 PLA + 2% Atmer 190 3 PLA + 3% Atmer 190 3 Floreon PLA blend - blank > 40 Floreon PLA blend + 2% Atmer 190 1 19 Additives in Biopolymers - 2023 7.E+14 2.E+11 3.E+10 2.E+14 1.E+11 1.E+08 1.E+10 1.E+12 1.E+14 1.E+16 Blank PLA 2% Atmer 190 3% Atmer 190 Blank Floreon PLA blend 2% Atmer 190 Surface Resistivity (Ω) Atmer 190 decreases the time it takes to dissipate 50% of the initial charge, compared to blank PLA and blank Floreon PLA blends • Atmer 190 can be added to polymers as a masterbatch, during compounding or directly in extrusion or injection molding • Atmer 190 is recommended at the following doses: - PLA: Up to 3% - Floreon PLA blends: Below 3% * PLA based films supplied by Floreon™
  • 20. © 2022 Cargill, Incorporated. All rights reserved. Effect of Atmer 190 on Mechanical Properties • Tests conducted using ASTM D638 20 Additives in Biopolymers - 2023 2% of Atmer 190 has no major effect on tensile properties of either PLA or PLA blends* * PLA based films supplied by Floreon™ 0 0.5 1 1.5 2 2.5 Blank PLA 2% Atmer 190 Blank Floreon PLA blend 2% Atmer190 Young's modulus, E (GPa) 0 10 20 30 40 50 60 70 Blank PLA 2% Atmer 190 Blank Floreon PLA blend 2% Atmer190 Tensile strength, UTS (MPa) 0 50 100 150 200 250 300 350 400 450 Blank PLA 2% Atmer 190 Blank Floreon PLA blend 2% Atmer190 Strain at break, ε (%)
  • 21. © 2022 Cargill, Incorporated. All rights reserved. 21 Additives in Biopolymers - 2023 Blank PLA PLA + 2% Atmer 190 PLA + 3% Atmer 190 Floreon PLA blend - blank Floreon PLA blend +2% Atmer 190 Effect of Atmer 190 on Optical Properties Atmer 190 has no effect on either the haze or color of PLA and Floreon PLA blends* * PLA based films supplied by Floreon™ Data name Haze L a b c h Blank PLA 0.2 97.1 -0.02 0.27 0.27 93.72 PLA + 2% Atmer 190 0.22 97.12 -0.01 0.25 0.25 93.23 PLA + 3% Atmer 190 0.86 96.99 -0.02 0.28 0.28 93.41 Floreon PLA blend – blank n/a 66.82 -0.84 -4.38 n/a n/a Floreon PLA blend +2%Atmer 190 n/a 65.48 -0.8 -4.29 n/a n/a
  • 22. © 2022 Cargill, Incorporated. All rights reserved. Permanent Anti-Static Additives 22 Additives in Biopolymers - 2023 • Ionphase Inherently Dissipative Polymers (IDP), also known as ion conductive polymers, reduce the resistivity of the polymer providing control and safety for static related issues • These additives offer an immediate and permanent effect, are humidity independent and offer good compatibility with host polymers with minimal change to the properties of the host polymer • Ionphase additives are suitable for compounding, extrusion or injection molding, and generally can be recycled • Ionphase is suitable for use in polymers including: – PLA & PLA blends – PBS • Recommended grade: – Ionphase trSTAT