CHAPTER I

Introduction

 Why do we need to come up with this plant?

What is a bio plastic?

https://www.activesustainability.com/environment/what-are-bioplastics/

http://whatis.techtarget.com/definition/bioplastic

Manufacturer of bio plastics here in Philippines

https://www.environmental-expert.com/companies/keyword-bioplastic-

5342/serving-philippines

http://www.sugaronline.com/website_contents/view/1238307

http://www.starchware.ph/about/

Objectives of Design

General Objectives

 Direct to the Point

Specific Objectives

 Technical Aspects

 Process Integration

 Financial Aspects
  Market Feasibility

Background of the Study

Limitation of Study

 Product Level

 Capacity of the plant

 Requirements of raw materials

 Operation of the plant

Plant Location

 Raw material availability

 Corns

o Cagayan Valley (Region II)

http://countrystat.psa.gov.ph/?cont=16&r=2

http://archives.pia.gov.ph/?m=12&sec=reader&rp=7&fi=p10020

5.htm&no=67&date=02/05/2010

 Eggshells

o San Jose, Batangas (Region IV-A)

https://www.pressreader.com/philippines/manila-

bulletin/20171018/281663960241311

 Energy and water availability

 Land adequacy

 Transportation facilities

 Labour site and site topography

Years of Projection

 Market and marketability

 Market limitation

 At least 25 years

Technical Limitations

 Equipment limitations

 Environment Limitations

 Laws and Regulations

 Financial Limitations

Significance of the Study

Definition of Terms

CHAPTER II

Literature Survey

 Historical and conceptual

https://bioplastics.weebly.com/history.html

https://pubs.acs.org/doi/abs/10.1021/acs.jafc.7b00133

Introduction
CONCEPTUAL BACKGROUND

RAW MATERIALS

A. Cornstarch

Corn starch, cornstarch, cornflour or maize starch or maize is the starch

derived from the corn (maize) grain. Maize or corn, as food, it is known for its

richness in carbohydrates that its abundant starch provides. Waxy corns are

used specifically for starch production and to improve the texture of baked

snacks. Waxy maize starch is composed of 100% amylopectin, which affects the

thickening and extrusion properties of its meal and starch.

Corn starch is currently the main raw material being used in the

manufacture of bioplastic resins such as Polylactic acid (PLA).

Figure 2.1 Corn Starch

 Figure 2.2 Corn
Generation

About 70 percent of our total corn production is consumed as human

food; the rest is used for livestock and poultry feeds. Corn is also used in our

industry in manufacture of corn by-products like corn starch, textile, paints, corn

oil, paper, etc.

Table 2.2 shows that corn production in 2017 reached 7.9 million tons, up

10 percent from 7.2 million ton in 2016. Area harvested increased to 2.55 million

hectares from 2.48 million hectares in 2016, while yields improved 7 percent to

3.1 tons per hectare from 2.91 tons per hectare. The major corn producing areas

in 2017 include the Cagayan Valley, Northern Mindanao, and Central Mindanao

regions. Harvest area may rise due to more plantings in Cagayan Valley, Central

Luzon, CALABARZON, MIMAROPA and Zamboanga Peninsula due to favorable

weather during planting period and continuous government interventions on

hybrid seeds and fertilizer support (Philippine Statistics Authority, 2017).

 Table 2.2
Corn volume of production, Philippines, 2013-2017

Q 2013 2014 2015 2016 2017

Corn 7,377,293.30 7,770,602.74 7,518,755.72 7,218,816.55 7,914,908.49

Source: Philippine Statistics Authority, 2018

B. Eggshells

Eggshell is an agricultural waste largely considered as useless and is

thrown away mostly because it contributes to pollution. It is mainly composed of

calcium carbonate(95%) but also of calcium phosphate and magnesium

carbonate.

It seems more likely to be used as an additive in a composite plastic. In a

journal entitled “Study of the Physical Properties of the Hen’s Eggshell in

Relation to the Function of Shell Secretory Glands”, the data from 3,998 eggs

show that the breaking strength and the thickness of eggshell are in the average

4.46 kilograms and 0.311 millimeters.

Vijaya K. Rangari, Ph.D of Tuskegee University performed experiments

with several plastic polymers and his research on adding eggshell nanoparticles

to a bioplastic was presented at the American Chemical Society’s 251st National

Meeting & Exposition. They found out that nano-sized eggshell particles add

strength to the bioplastic material and make them far more flexible than other

bioplastics on the market.

 Figure 2.3
Eggshells

Generation

The chicken egg production during the first half of 2017 was estimated at

242,988 metric tons. This posted an increase of 4.49 growth relative to egg

production the same period the previous year. In the fourth quarter of 2017,

chicken posted the biggest growth in the gross output value at 18.10 percent and

this was attributed to improvement in production and prices. A similar trend was

noted for duck eggs as gross earnings went up by 2.53 percent. Table 2.3 shows

the volume of production in poultry from 2015-2017.

 The output in the poultry subsector continued its uptrend with this year’s

4.73 percent increase. It accounted for 15.40 percent of the total agricultural

output during the reference quarter. There were newly opened commercial farms

in CAR, Western Visayas and SOCCSKSARGEN which contributed in the 3.78

percent growth in chicken production this quarter. Chicken dressed in poultry

dressing plants also increased in producing regions like Central Luzon,

CALABARZON, Western Visayas, Central Visayas, Northern Mindanao, Davao

Region and SOCCSKSARGEN.

Production of chicken egg went up by 9.97 percent due to expansion of

some commercial layers farms in Ilocos Region, Central Luzon, CALABARZON,

Eastern Visayas, Davao Region and SOCCSKSARGEN. Moreover, the

production of native chicken eggs grew in Ilocos Region, Cagayan Valley, Bicol

Region, Western Visayas, Central Visayas, Zamboanga Peninsula, Davao

Region and Caraga because of the increase in adult female and higher efficiency

levels. Duck egg production inched up by 0.37 percent. This was due to the

higher number of adult female/laying flock in both backyard and commercial

farms in Ilocos Region, CALABARZON, MIMAROPA, Bicol Region, Zamboanga

Peninsula, Northern Mindanao, SOCCSKSARGEN and Caraga. Also, expansion

in some commercial duck farms in CALABARZON was noted. The decline in

duck production at 5.02 percent was attributed to lesser available stocks for

slaughter in CAR, Ilocos Region, SOCCSKSARGEN, Caraga and ARMM and the

lag effect of avian flu that occurred in the third quarter of 2017 in Central Luzon.
 Table 2.3
Poultry volume of production, Philippines, 2015-2017

POULTRY 2015 2016 2017

Chicken 1660.82 1674.51 1745.89

Duck 33.94 32.22 31.09

Chicken Eggs 444.55 461.72 492.41

Duck Eggs 42.40 44.16 45.43

Source: Philippine Statistics Authority, 2018

C. Polybutylene adipate terephthalate

PBAT (polybutylene adipate terephthalate, in short, polybutyrate) is a

biodegradable random copolymer. It is a compostable biopolymer with similar

properties like low density polyethylene (LDPE). PBAT is an aliphatic-aromatic

copolyester, mainly derived from the monomers 1, 4-butanediol, adipic acid, and

terephthalic acid with a tunable balance of butylene adipate and butylene

terephthalate. Figure 2.4 shows the chemical structure of PBAT.

PBAT combines good mechanical and thermal properties as shown in

Table 2.4 with biodegradation ability. It has been reported to be degraded in a

few weeks by lipases from Pseudomona cepacia and Candida cylindracea so it

became a promising candidate for use as a biodegradable packaging.

Moreover, it has good thermoplastic and fully biodegradable properties and a

high elongation at break, low water vapor permeability, and good processing

properties that are suitable for preparation of packaging films, compost bags, and
agricultural mulching films. The flexibility and toughness of this polymer makes it

ideal for blending with another biodegradable polymer that is strong and rigid for

bottle production (American Institute of Chemical Engineers (AIChE), 2008).

PBAT films can be prepared using extrusion-casting, extrusion blowing,

thermocompression, and solvent casting methods. Extrusion of PBAT is the

preferred method for industrial production of films and thermocompression is also

a simple and convenient method for production of films without use of a solvent.

Figure 2.4 Chemical Structure of PBAT

Figure 2.5 PBAT

 Table 2.4
Thermal and mechanical properties of PBAT

Glass transition temperature (°C) 61

Crystallization temperature (°C) 123
Melting temperature in peak (°C) 110-120
Density (g/cm3) 1.25-1.27
Ultimate tensile strength (MPa) 10-36
Young´s modulus (MPa) 609
Tensile strain (%) 20-560

Source: Ing. Adriana Gregorová , Ph.D., 2013

Generation

Major bio-based biodegradable polymers include polyhydroxyalkanoates

(PHAs), polyhydroxybutyrate (PHB), and related copolymers; polylactic acid

(PLA); regenerated cellulose; and starch-based polymers (thermoplastic starch).

Commercially significant petrochemical-based biodegradable polymers include

copolyesters such as polybutylene adipate terephthalate (PBAT) and

polybutylene succinate adipate (PBSA), polybutylene succinate (PBS),

polycaprolactone (PCL), and polyglycolic acid (PGA).

PBAT has mostly been produced by one big company, BASF, but a new

player, Jinhui Zhaolong High Technology, entered the market in 2014. The global

PBAT market is predicted to grow at 14.89% CAGR to reach USD 636.96 million

by the end of 2023. PBAT is gaining prominence in the global market with the

rising usage in various end use industries such as packaging, agriculture &

fishery, consumer goods, coatings, and others (Market Research Future, 2018).
Some of the key market factors that positively influence the PBAT market growth

are, rising demand from packaging industry, growing production of PBAT based

production, increasing awareness regarding the benefits associated with PBAT,

and rising urbanization.

PRODUCTS

Historical background

Physical and chemical properties

Applications

o Tissue Regeneration Surrogate

o Biodegradable Mulching Film

o Food Packaging

o Antimicrobial Packaging

o Thrash Bagging

Manufacturing Process

CHAPTER III

Market Study
 Bioplastics are those plastic materials that are manufactured by using

natural resources. There are two categories of these plastics available in the

market — biodegrable bioplastics and non-biodegradable bioplastics. This

chapter presents the review for the local and global market for the proposed

bioplastic from eggshells plant. The major players and competitors, historical and

projected global demand, market share, product distribution and strategies,

channel by distribution, price study and marketing strategy are also presented.

GLOBAL MARKET

What boost the bioplastics market across the globe is the large availability

of renewable feedstocks, high fossil fuel prices, increase in the dependence on

fossil fuels, utilization of bio-based raw material, the shift in consumer preference

for eco-friendly packaging, and increased government initiatives & activities to

promote the use of biodegradable plastics. Furthermore, some other key factors

that drive the market growth is the increasing adoption in new end user industries

and favorable government policies for the use of eco-friendly and biodegradable

products because of decreased number of petroleum reserves and the

increasing cost of petrochemicals.

Global bio-plastics market comprises biodegradable plastics which

includes polyester, polylactic acid (PLA), polyhydroxyalkanoates (PHA), starch

blends, cellulose esters and others and non-biodegradable plastics which

includes bio-PE (polyethylene), bio-PET (polythene terephthalate), bio-PA

(polyamide) and others. Their key applications across the globe include

automotive, construction, packaging, consumer goods, electrical & electronics,

agriculture, textile, automotive, FMCG and others. The regional segmentation

includes Middle East & Africa, Asia Pacific, Europe, Latin America and North

America. Furthermore, it is bifurcated into major countries such as U.S., Canada,

Mexico, Poland, Russia, UK, Germany, France, China, India, Japan, ASEAN,

South Korea, Brazil, and Argentina.

The market is growing rapidly because more and more companies are

entering this market with newer innovations and applications in automotive and

electronics. Europe was the leading market of bio-plastics during the past

decades because of limited crude oil reserves. And during the years to come, the

changing dynamics in UK, France, and Germany is likely to fuel the market’s

profit margin. The ban on usual shopping carrier bags pioneered in Italy, is

projected to contribute to the commercialization of bio-plastics. Furthermore,

adoption of this trend in the UK and France is also expected to boom the demand

for bio-plastics. For instance, bio-plastic carrier bags helps minimize garbage and

encourage augmented food waste collection and develop organic recycling

ensuing in improved soil structure and quality. North America is also an important

market of bio-plastics. The new regulations that will help to promote the usage of

bio-based materials are the major driving factor of the market in the region. The

Asia Pacific is one of the fastest growing markets of bio-plastics within the

forecast period. Due to emerging packaging industry in Brazil and Argentina,

Latin America is projected to witness significant growth. Moreover, high

penetration of environmental concerns coupled with the great support of

government bodies is predicted to fuel the demand for bio-plastics in the region

in the near future. Middle East & Africa are also expected to experience the

moderate growth of bio-plastics in the near future due to the vast investment by

the international company such as Taghleef Industries for the bio-plastics project.

Moreover, emerging industries such as food & beverage packaging, personal

care product industries and textile industries in the region are projected to grow

the business of bio-plastics materials in the region in the coming years.

The global bioplastics production capacity is set to increase from around

2.05 million tonnes in 2017 to approximately 2.44 million tonnes in 2022. The

consumption of drop-ins bioplastics (Bio-PE, Bio-PET 30, Bio-PA and others)

would continue to dominate the overall Bioplastics Market through to 2020, owing

to its overall properties and wide applications similar to traditional plastics (PE,

PET and PA among others). Bio-PET 30 would be the fastest growing segment

in the non-biodegradable bioplastics market, as it delivers same performance as

synthetic PET with regards to re-sealability, versatility, durability, appearance,

weight and recyclability.

 Global production capacities of bioplastics in 2017 (by market
segment)

Total:
2.05
million
tonnes
in %

Packaging Consumer goods Automotive and transport

Building and construction Textiles Agriculture and horticulture
Electrics and electronics Others

Source: European Bioplastics, nova-Institute (2017).

https://globenewswire.com/news-release/2018/01/16/1289496/0/en/Global-Bio-

Plastics-Market-Will-Reach-USD-35-47-Billion-by-2022-Zion-Market-

Research.html

https://www.european-bioplastics.org/global-market-for-bioplastics-to-grow-by-

20-percent/

https://www.freedoniagroup.com/industry-study/world-bioplastics-3089.htm

https://www.zionmarketresearch.com/report/bioplastics-market

http://industry-experts.com/verticals/chemicals-and-materials/bioplastics-a-

global-market-overview

LOCAL MARKET
 In the Philippines, industries such as the electronics, construction, food,

cosmetics, packaging, and automotive are aligned with the viability of

the plastics industry. And due to bioplastics’ unique characteristics—biobased,

sustainable and biodegradable—drastically reducing the leakage of plastics into

natural systems (in particular the ocean) and other negative externalities, some

companies and brands here in the Philippines are using bio-plastics materials in

their products.

The bioplastic industry has high potential for growth if the focus is not just

the replacement of current plastic applications but innovation of newer properties

and newer applications as well. Moreover, Philippines is the highest and most

expensive importer of fossil fuel in Asia and so the need for bioplastics is focused

to be driven by this statistic and the fact that bioplastics were found to be

superior to petroplastics in terms of energy efficiency, petroleum consumption,

and carbon emissions. Being based on renewable and/or bio-degradable

resources, bioplastics enable a positive contribution towards sustainable

products in material and end of life phase.

MAJOR PLAYERS AND COMPETITORS

Some of the major players competing in this market are NatureWorks,

Dupont, Braskem (BAK), Toray Industries, Lanxess AG, Bayer, BASF, and

Eastman.
 NatureWorks. It is an independent company invested in by Thailand's

largest chemical producer, PTT Global Chemical, and Cargill, an international

producer and marketer of food, agricultural, financial, and industrial products and

services. It is the first company to offer a family of commercially available

polymers derived from annually renewable resources with the cost and

performance to compete with petroleum-based packaging materials and fibers.

The company has achieved this breakthrough by applying its unique technology

to the processing of natural plant sugars to create a proprietary polylactide

polymer, the world's first greenhouse-gas-neutral* polymer, which is marketed

under the NatureWorks® PLA and Ingeo™ fiber brand names. They use plants

to transform greenhouse gases into sugars they can ferment. Their R&D team is

also working on new technology to skip plants entirely. Their technology converts

lactic acid into a portfolio of Ingeo PLA (polylactic acid) polymers each tailored to

a set of specific performance attributes. Ingeo polymers and fibers are used by

their partners to make a wide-range of innovative products from films to yogurt

cups to baby wipes.

DuPont. DuPont is the world's eighth-largest chemical producer by

chemical sales. It is the American conglomerate that invented Nylon, Neoprene

and Kevlar® and is a leader in thermoplastics, elastomers and biopolymers.

Dupont Performance Polymers is working on development of whole new families

of plastics based on renewable resources as part of an ambitious program to

make more than half of its plastics and chemical monomers from renewable
resources within the next 10 years. DuPont made its first major foray

into bioplastics with the launch of partially corn-based Sorona polytrimethylene

terephthalate (PTT) in 2006 using 1,3 propanediol (PDO) made in a production

joint venture with Tate & Lyle.

Braskem. It is the largest resin producer in the America with 36 industrial

plants in Brazil, the US and Germany. It produces over 16 million tons of

thermoplastic resins and other petrochemical products annually. Braskem is the

world leader in the production of biopolymer, with the green polyethylene – I’m

green ™, a thermoplastic resin produced from ethylene made from sugarcane

ethanol, a 100% renewable raw material which helps reduce greenhouse gas

emissions. The resin, whose properties are identical to those of conventional

polyethylene, is extremely versatile in terms of applications and is also

recyclable. I'm greenTM Polyethylene is a plastic produced from ethanol

sugarcane, a renewable raw material, while the traditional polyethylene uses

fossil sourced raw materials such as oil or natural gas. For this reason I'm

greenTM Polyethylene captures and fixes CO2 from the atmosphere during its

production, helping to reduce greenhouse gases emission.

Toray Industries. Toray Industries is a Japanese company. Toray Group

is an integrated chemical industry group developing its business in 23 countries

and regions worldwide. Toray Group fuses nanotechnology into its operations,

using organic synthetic chemistry, polymer chemistry and biotechnology as its

core technologies. Toray uses a part-plant, part-petroleum mixture so that the

parts meet the heat and physical wear requirements for automobile parts, but

Toray says it will work on creating materials that have higher percentages of

plant-based materials and still meet the requirements. The company's past work

with bioplastic includes computer cases for Fujitsu and multifunction office device

parts for Canon. Toray has also worked with Patagonia on recycling nylon for

its Common Threads clothing recycling program.

Bayer. Bayer MaterialScience’s research into carbon dioxide as a new

raw material for plastics is delivering further results. In laboratory tests, the

company has succeeded in significantly further reducing the need for petroleum

at precursor level through the incorporation of CO2. Bayer MaterialScience sees

itself as a pioneer when it comes to future applications for CO2.

Eastman. Eastman TRĒVA™ engineering bioplastic is a new cellulose-

based thermoplastic that offers both high performance and reduced environment

impact. Eastman examined the material’s chemical resistance in a 24-hour test,

pitting it against acrylic, PC, PC/ABS and neat ABS, with Treva fairing the best.

Eastman also boasted about the material’s processing ease, noting that in a .75-

mm spiral-flow test, it performed better than PC and PC/ABS, while being

comparable to ABS. The company also ran a hot runner test against acrylic, PC,

ABS and PC/ABS, utilizing a valve-gated nozzle with a small pin gate, and once
again Treva exhibited high flow. In terms of appearance, Eastman said Treva

results in parts with high gloss and clarity, as well as a “warm” touch and feel.

The material takes color well, allowing for high pigment saturation. Given its

properties, Eastman sees applications in eyeglass frames, wearable electronics,

headphones, and any other number of items that require durability and come in

contact with the skin. It is also suitable for housings, cases and other applications

with high levels of design intricacies.

GLOBAL DEMAND AND SUPPLY OF BIOPLASTICS

Global Historical Demand for Bioplastics

Since past decade, demand for bioplastics is increasing. This is due to

growing awareness concerning environmental conservation, use of bio-based or

natural resources for manufacturing materials and formulation of various

regulations across countries for effective use of natural resources and waste

management.

Shown in Table. is the global demand for the bioplastics from 2008-2017.

Global Historical Supply for Bioplastics

Shown in Table. is the global supply for the bioplastics from 2008 – 2017.
 Year Supply (in thousand
tonnes)
2008 180

2009 249

2010 1016

2011 1161

2012 1395

2013 1581

2014 1697

2015 3952

2016 4156

2017 2054

Source: European BIoplastics

Figure. shows the graphical representation of the global supply for

bioplastics
 4500
SUPPLY (THOUSAND TONNES) 4000

3500

3000

2500

2000

1500

1000

500

0
2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
YEAR

biodegradable bio-based/non-biodegradable

Figure. Global Supply of Bioplastics

Table. shows the standard deviations of the four statistical methods of

projection for the global supply of bioplastics.

 Table

Standard Deviation Values for the Global Supply of Bioplastics

Statistical Method Standard Deviation

Arithmetic Straight Line

Arithmetic Geometric Curve

Statistical Straight Line

Statistical Parabolic

PROJECTED VALUES

Arithmetic straight line method (ASL), arithmetic geometric method (AG),

statistical parabolic method (SP), and statistical straight line method (SS) were

used to determine the projected values of bioplastics global supply and demand.

Projected Global Demand and Supply of Bioplastics

Table presents the projected values for the global bioplastics demand.

The values were obtained using Statistical Parabolic Method with standard

deviation of .

Market Share

 First year to operate

Product Distribution and Strategies

Channel by Distribution

Price Study

Marketing Strategy

CHAPTER IV

Gantt chart

 Project Schedule

 Feasibility study

 Engineering design/Plant design

CHAPTER V

Process Description

A. Product Specification

B. Raw Materials

C. Manufacturing Process

a. Preparation of raw materials

b. Pretreatment