FORMULATIONS FOR BIODEGRADABLE PLASTICS FOR A GREENER FUTURE

The current patterns of production and consumption of conventional plastics are unsustainable. Conventional plastics are non-biodegradable, leading to visible pollution in soil, marine environments and the air when discarded, landfilled or burnt. Products that are practically non-recyclable, such as plastic mulch films used in agriculture, often end up being disposed of in the environment or break down into microplastics, causing ecological issues with frequently underestimated consequences. To address the pollution problem, there is a growing demand for biodegradable alternatives for specific product lines. These alternatives must meet performance requirements, making it essential to tailor the properties of biodegradable polymers. The CSIR specialises in modification processes and a range of formulations designed to address specific needs. These include biodegradable mulch films suitable for crops with varying lifecycles and rigid formulations suitable for biomedical device casings. 

CSIR C3 offers a range of modification processes and biodegradable polymer plastics formulations for commercial uptake. These formulations 2 are tailored for flexible and rigid applications in packaging, agriculture and medical device casing. The formulations contain up to 40 wt% locally derived natural materials, undergo complete composting, converting into carbon dioxide, water and biomass without any release of toxic residues. They are well-suitable for instances where the end-of-life scenario supports biodegradation or composting, such as in the case of biodegradable mulch films. 

While several commercial biodegradable polymers are two to four times more expensive than conventional polymers, the CSIR-developed biodegradable plastics have been formulated to achieve cost reductions by up to 30%. Unlike imported neat or formulated equivalents, our solution is customised to address specific needs.  In contrast to imported equivalents, the CSIR uses up to 40 wt% locally sourced material to unlock functionalities that would otherwise remain inaccessible. The approach allows for customised formulations, for instance, controlled biodegradability rates and biodegradable mulch films for short-, medium- and long-term crops.  

Licensees of the technology will be able to manufacture, market and sell formulated and compounded pellets to converters. These converters, in turn, will produce final products such as composting bags, agricultural mulch films, diapers or plant clips for distribution to end-users. The compounding business’s primary revenue stream will be derived from the sale of these biopolymer pellets, while CSIR C3 will receive royalties based on these sales. To ensure a consistent supply of base biopolymers, such as polybutylene adipate-co-terephthalate, the business may want to partner, through a joint venture, with major producers.  

An estimated R40 million is required to establish a compounding business that will cater to the addressable market. This budget includes R10 million allocated for pre-commercialisation activities to de-risk the process. The payback period for this investment is five years, with a net present value of R54 million, calculated at an 18% discount rate, with an internal return rate of 30% over a 10-year analysis period.