Lapol is a renewable biopolymer resin technology company and innovator of the revolutionary US patented Lapol bioplasticizer. Lapol sells its resin to polymer compounding companies and end user converting companies that seek biodegradable/compostable and renewable/sustainable polymer applications for products such as: bags, containers, food service disposables, electronic components, credit cards, toys and a variety of other products that are injection molded, extrusion coated or films that are blown or cast.
Product and Technology
The Lapol patented technology is based on the unique polymerization of lactic acid and other monomers to specifically blend with poly lactic acid (PLA) and traditional petroleum derived polyolefins. Polymerization of Lapol uses like polymers thereby negating the need for additional costly compatibilizers. The resulting products have increased elongation while maintaining clarity and modulus (stiffness). Lapol has been designed to be biodegradable and compostable, renewable and sustainable, high performing and cost-competitive compared to other plasticizers.
Marketplace
When biopolymers were first introduced to the marketplace, the raw materials costs for petroleum-based polymers were as low as $0.25-$0.50/lb. and biopolymers were in their infancy with costs ranging from $2.50-$10.00/lb. Since the middle 90's, the biopolymer industry has steadily grown 20-30% each year and the resins have been further commercialized and brought to market at more reasonable costs ranging from $0.75-$1.60/lb., while oil prices have surged and plunged and are likely to surge again the traditional petroleum-based polymers have ranged from $0.40-$1.25/lb. With this change in cost structure, the biopolymers have become more competitive and economical to traditional petroleum-based non-degradable polymers.
Although biopolymers have become more cost effective, they typically do not perform well on their own; rather, they must be modified and compounded with plasticizers to reach sufficient fitness for use properties to compete with petroleum-based resins. Polylactic acid (PLA) and PHA have high rigidity and are unsuitable for applications that require flexibility and toughness. The most common technique to make PLA and PHA flexible is to add a plasticizer or to compound in more flexible polymers. The predominantly used and commercially available resin used for both PLA and PHA is an aromatic/aliphatic copolyester which are biodegradable, but not at all renewable since they are 100% derived from petroleum. Blends made from these materials tend to have reduced modulus (stiffness) and they are not optically clear. These copolyesters are expensive, in short supply and are often on allocation with only limited production capacity. Lapol, however, is made from predominantly renewable resources, maintains modulus, clarity and is readily available at a lower cost. Lapol is also up to twice as effective pound for pound for elongation properties, thus, inasmuch as Lapol and the aromatic/aliphatic copolyesters are similarly priced pound for pound, the elongation cost per pound can be one quarter to one half the cost by using Lapol bio-derived resin.
The current global capacity of the major producers of PLA is 150,000-300,000 tons in Nebraska (NatureWorks) and other companies in China and Europe. There is approximately 150,000 tons of PHA coming on the market in the US, China and Brazil. Each of these plants produces products that need to be plasticized to be used across a wide variety of applications, such applications include:
Extrusion coated paper: cold cups, hot cups, food wraps, deli paper, butcher paper, etc.
Thermoforming: packaging products, trays, plates, bowls and other shallow draw products
Blown and cast film: bags and agricultural films.
Each of the products listed above require different loadings of Lapol to achieve certain properties that can range from 5%-20% loading, but a typical loading on most products is about 5%-10%. Additional research is pending on similar grades of Lapol renewable resin to be used in oil-based polymers such as polyolefins and PVC.
Properties
The Lapol bioplasticizer is principally sold based on the following properties:
Biodegradability/Compostability (ASTM D6400, EN 13432 & ISO 17088 compliance)
Renewability/Sustainability (predominantly derived from plant sources)
Compatibility and miscible (no need for additional compatibilizers during compounding)
Flexibility without compromising stiffness
Clarity (little clarity reduction of PLA)
FDA compliant (screening study is complaint with 21 CFR 175.300, additional compliance is underway)
Typical Physical
Properties of Compounded Lapol 108 in PLA
Lapol 108 resin compounded into NatureWorks® , LLC 4042D
(biaxially oriented film
– general purpose grade) polylactic acid at 0.5 mm thick films.
Physical Property
ASTM Test
5% Lapol in PLA
10% Lapol in PLA
Elongation
@ Break
D 638
60%-100%
80%-160%
Tensile
Stress @ Yield MPa
D 638
77-84
57-59
Tensile
Modulus MPa
D 638
2160-2313
1700-1786
Specific
Gravity
D 1505
1.23 g/cc
1.22/g/cc
Melt
Flow Index @ 190⁰C at 2.15kg
D 1238
3-4 g/10 min.
9-11 g/10 min.
It is recommended that Lapol be added according to the properties that are desired for the particular application. Typical applications require between 5% and 10% Lapol bioplasticizer. Note that 50%-75% less Lapol is required to achieve >100% elongation when compared to 100% petroleum based aliphatic aromatic copolyesters.
Intellectual Property
Lapol has a been granted a United States Patent with many foreign patents pending and others in preparation for application.
