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FC 45140 Polylactic Acid/PBAT Blown/Cast Film Compostable Blend

    • Название продукта: FC 45140 Polylactic Acid/PBAT Blown/Cast Film Compostable Blend
    • Сайт Factroy: Округ Юду, Ганьчжоу, Цзянси, Китай
    • Запрос цены: admin@ascent-chem.com
    • Производитель: Ascent Petrochem Holdings Co., Limited
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    Спецификации
    Код ТН ВЭД 592845

    Как аккредитованная фабрика компостируемой смеси с полимелочной кислотой FC 45140 /PBAT, мы соблюдаем строгие протоколы качества - каждая партия подвергается строгим испытаниям для обеспечения последовательных стандартов эффективности и безопасности.

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    Применение компостируемой смеси полимолачной кислоты FC 45140/PBAT

    FC 45140 is a pre-compounded PLA/PBAT film resin intended for blown-film and cast-film converting lines where the finished article must meet industrial compostability disintegration thresholds. Qualification is governed by the overlap between polymer-phase rheology, moisture uptake kinetics, and the specific disintegration test environment; therefore the applications below are restricted to monolayer or coextruded film structures in which FC 45140 forms the heat-sealable, load-bearing ply. Non-compostable tie layers, solvent-borne laminating adhesives, and structures that embed the film in a non-disintegrating matrix are outside certification scope. Processing prerequisites shared across all downstream routes are preliminary moisture removal to below 300 ppm, die melt temperatures not exceeding 178 °C, and reclaimed trim reincorporation after screening below 300 ppm moisture. Melt volume-flow rate measured by ISO 1133-1:2022 should be recorded against the certificate of analysis at incoming QC; lot-to-lot variation in melt viscosity changes extruder mean residence time and purge behaviour on high-speed lines.

    Certified organic waste collection films converted from FC 45140 are qualified under EN 13432 or the equivalent certification scheme operating through ISO 17088; disintegration is assessed under ISO 20200 at 58 ± 2 °C and biodegradation under ISO 14855-2. The blend is metered at 100 parts by weight as the sole film-forming polymer. Caddy liners are typically extruded at 15–20 µm, drawstring municipal sacks at 20–25 µm, and kitchen compostable bags at 12–18 µm, with gauge selection driven by wet organic waste mass and collection interval rather than by film tensile strength alone. At 0.5–1.5 wt% of a PLA-compatible slip/antiblock masterbatch is added to control blocking at rewind; the masterbatch must be dried with the pellet stream and not introduced through a side port at ambient humidity. Blown-film conversion uses a barrier screw with an L/D ratio of 30:1–36:1, die gap of 1.2–1.8 mm, and a blow-up ratio of 2.5:1–3.5:1; die-exit melt temperature is held at 158–172 °C. Processors report that temperatures above 178 °C generate gel particles in the PLA fraction, while temperatures below 155 °C produce die-lip build-up from PBAT-rich domains. At RH exceeding 60%, pre-drying at 60 °C for 4–6 h is required before extrusion. Terminal article types include star-seal caddy liners, tie-handle kitchen bags, and drawstring sacks for municipal organic waste diversion; side-gusseted tub liners require the upper gauge limit to resist wet caddy sidewall abrasion.

    Standard or methodClause / test designationApplication to FC 45140 compostable films
    EN 13432Clauses 6–8Industrial compostability packaging; ≥90% disintegration in 12 weeks; ≥90% biodegradation in 180 days
    ASTM D6400SpecificationUnited States industrial compostability; ≥90% biodegradation relative to positive control
    ISO 17088SpecificationGlobal harmonised framework; references ISO 14855-2, ISO 20200
    ISO 20200Test methodLaboratory-scale disintegration at 58 ± 2 °C
    ISO 527-3Film tensileTensile strength and elongation at break for caddy liners, carrier bags, mulch
    ISO 6383-2Trouser tearTear resistance after thickness reductions and regrind addition
    ASTM D1709Method ADart drop for retail carrier film and mailer plies
    ASTM F88Seal strengthAdhesive or heat-seal integrity for mailers and overwraps

    Why Does Dart Impact Strength Fall Below 200 g at 18 µm in Retail Carrier Bags?

    The melt-strength envelope of the PLA/PBAT blend governs retail t-shirt bag production. When film gauge falls below 18 µm, dart impact measured by ASTM D1709 Method A can decline below 220 g if frost-line height is moved too far from the die or if blow-up ratio is increased above 4.0:1; the reduction is attributed to orientation-induced strain in the PLA-rich phase before PBAT droplets can relax. Compliance for retail compostable carrier bags is established through EN 13432 or ASTM D6400, and the bag must satisfy tensile criteria under ISO 527-3: for a 20 µm film, machine-direction elongation at break is maintained above 300%. The compound is fed at 100 wt%; post-industrial trim from vest handle punching may be reintroduced at up to 15 wt% after drying to below 300 ppm and screening through a 20-mesh screen pack. Blown-film lines with 55–75 mm grooved-feed extruders and L/D 33:1 are used, with dual-lip air ring and internal bubble cooling stabilising the bubble at 2.8:1–3.5:1 BUR. Die gap is set at 1.4–1.8 mm, and die-exit melt temperature is limited to 162–170 °C. Terminal products include vest-style checkout bags, wave-top market bags, and bottom-seal carrier sacks; the punched vest-handle skeleton is the dominant source of post-industrial regrind, and failure to screen it below 300 µm contributes to die-lip streak defects. Non-compostable polyethylene dilution must be avoided because even 2–3 wt% contamination invalidates the material identity required for EN 13432 certification.

    In soil-biodegradable mulch film production, EN 17033 establishes the full validation framework for FC 45140-based films below 25 µm nominal gauge: soil biodegradation under ISO 17556, ecotoxicity screening, and absence of sharp fragment accumulation after soil incorporation. The blend is processed at 100 wt%, with carbon black masterbatch added at 2–6 wt% for light exclusion; higher carbon black loadings above 6 wt% are not recommended because screen pressure rises and PBAT-phase elongation under ISO 527-3 falls below the level needed for reliable field handling. Film gauge is set at 12–25 µm, with 15 µm used for one-season vegetable beds and 20–25 µm for longer strawberry tunnels; below 12 µm, mechanical fragmentation occurs too early to meet EN 17033 service-life expectations. Blown-film conversion uses 70–100 mm extruders with L/D 33:1–36:1, a 1200–1800 mm spiral mandrel die, and a blow-up ratio of 2.2:1–2.8:1; this lower BUR preserves tear resistance under ISO 6383-2 while allowing layflat widths from 1.0 m to 1.4 m. Melt filtration at 80–100 mesh is required ahead of the die because carbon black agglomerates larger than 150 µm initiate pinholes. Published data for this specific configuration is limited for multi-season tunnels above 20 µm; converters are advised to run field disintegration trials rather than extrapolate from short-cycle caddy-liner data. Soil incorporation after harvest is mandatory for certification. Terminal products include black, clear, and white-on-black mulch film rolls for tomato, maize, and lettuce cultivation; clear and black mulches occupy different soil-temperature management functions and are not interchangeable.

    When E-Commerce Mailer Film Replaces LLDPE in Postal Sortation

    Courier pouch and e-commerce mailer films converted from FC 45140 operate in a higher mechanical severity regime than disposal carrier bags: the film must survive conveyor pinch points, label adhesion on corona-treated surfaces, and adhesive flap seal integrity under ASTM F88 peel conditions. Compliance is demonstrated under EN 13432 or ASTM D6400, while the sealant face is corona treated to 38–42 mN/m and printed with water-based flexography; surface treatment above 44 mN/m can over-oxidize PBAT-rich domains and reduce hot-tack. The blend is used at 100 parts by weight with up to 15 wt% post-industrial regrind; film gauge is set from 50 µm to 80 µm for mailer plies. Monolayer rather than coextruded structures are generally used because a tie layer is not required; an adhesive-free construction avoids non-compostable chemistry that would invalidate the certification. Blown-film processing uses a 65–90 mm extruder with L/D 36:1, die gap of 1.8–2.2 mm, BUR 2.0:1–2.8:1, and frost line kept at 2.5–3.5 die diameters to balance stiffness and tear propagation. Cast-film lines with 80–120 mm extruders and chill roll temperatures of 12–18 °C are preferred where print gloss and gauge uniformity dominate; however, the cast route can lower Elmendorf tear under ISO 6383-2, and mailers intended for heavier items should use the blown route. Solvent-based inks are avoided due to migration and plasticizer incompatibility; only low-residue water-based or UV formulations are recommended. Terminal products include self-seal poly mailers, padded mailer outer plies laminated to paper or starch-based wadding, and tamper-evident courier pouches.

    Process variableBlown-film routeCast-film route
    Die gap1.8–2.2 mm0.6–0.8 mm
    Die-exit melt temperature162–170 °C165–172 °C
    Blow-up ratio2.0:1–2.8:1Not applicable
    Chill roll temperatureNot applicable12–18 °C
    Elmendorf tear under ISO 6383-2Higher MD/CD balanceLower absolute tear at equal gauge

    For short shelf-life produce flow-pack cast film, FC 45140 is used in gauges from 10 µm to 20 µm; the film is not a high-gas-barrier structure and is therefore limited to post-harvest windows where moisture vapour transmission, not oxygen exclusion, is the controlling parameter. Food contact compliance must be established for the finished article under Commission Regulation (EU) No 10/2011 with overall migration tested in 10% ethanol and 3% acetic acid simulants against the limit of 10 mg/dm², and in the United States through an appropriate FCN for the specific PLA/PBAT formulation; general food-contact approval must not be inferred from the polymer class alone. The blend is fed at 100 wt% with 0.5–1.2 wt% slip/antiblock masterbatch to stabilise rewind and produce a self-COF of 0.25–0.45. Cast-film lines use a slot die with die gap 0.6–0.8 mm, chill roll temperatures of 18–25 °C, and line speeds of 150–250 m/min; edge trim is reprocessed at not more than 10 wt% to avoid gel accumulation on the chill roll, which appears as visible specks in transparent wrap. Terminal products include pillow packs for leafy greens, citrus wraps, and lettuce sleeves, with laser or mechanical perforation added downstream by the converter; perforation geometry, not film formulation, controls respiration rate. This structure is unsuitable for modified-atmosphere packaging requiring oxygen transmission below 500 cm³/m²·day·bar unless an additional barrier layer is included.

    Foodservice Overwrap Seal Initiation and Condensation Limits

    Foodservice overwrap films based on FC 45140 are used to seal individual cutlery sets, napkin rolls, and tray wraps where the package must resist moisture condensation but still disintegrate in industrial compost. Regulatory compliance for these formats follows Regulation (EC) No 1935/2004 plus Commission Regulation (EU) No 10/2011; if the overwrap contacts unpackaged food, overall migration testing under 10-day 40 °C conditions must be completed for the specific formulation. The film is used at 100 wt% FC 45140, with 0.5–1.0 wt% of high-purity synthetic amorphous silica antiblock to prevent blocking at rewind, and gauge is maintained between 15 µm and 25 µm. Sealing is performed on side-seal or flow-wrap machines with constant-heat seal jaws set at 120–135 °C and dwell times of 0.3–0.6 s; seal initiation below 110 °C is not typical, and hot-tack strength drops sharply when jaw temperature falls below 105 °C. Blown-film lines with L/D 30:1–36:1 and die gaps of 1.2–1.6 mm are used, with BUR held at 3.0:1–4.0:1 to reduce directional tear. Terminal products include cutlery overwrap, napkin bands, and tray-seal lidding stock without high gas barrier; the film is not to be used for retort, hot-fill, or alcohol-containing food contact. Avoid amine-based anti-fog additives in this matrix; their interaction with PLA degradation products can accelerate acetic acid generation during extrusion and reduce seal consistency.

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    FC 45140 Polylactic Acid/PBAT Blown/Cast Film Compostable Blend is a pelletized melt-compounded formulation of poly(lactic acid) and poly(butylene adipate-co-terephthalate) plus a reactive epoxy-functional chain-extension package. The supplier’s formulation record identifies the nominal PBAT fraction as 40–50 wt%. The grade is intended for thin-gauge blown and cast film structures in which industrial compostability according to EN 13432:2000 or ASTM D6400-21 is specified. The compound is not a neat polymer within the meaning of ISO 1043-1:2011; it is a multiphase polyester blend. Published independent data for this specific product configuration are limited, and the values reported below are drawn from the supplier’s technical data sheet revision 2024-02 and from toll-processing records.

    On a production-scale monolayer blown film line with a 45 mm single-screw extruder using 30:1 L/D and a 100 mm spiral mandrel die, stable bubble formation was obtained at 175 °C melt temperature. The melt pressure before the screen pack remained between 180–220 bar at 60 rpm. When the melt temperature was raised to 190 °C, die-lip deposits increased within 30 min, and film dart impact dropped by approximately 20%. These observations are process-specific and do not constitute a guarantee for all production lines.

    What Are the Standardized Property Values for FC 45140?

    PropertyTest standardLot-release window
    Melt flow indexISO 1133-1:2022, procedure A, 190 °C/2.16 kg4.0–7.0 g/10 min
    DensityISO 1183-1:2019, method A1.23–1.27 g/cm³
    Vicat softening temperatureISO 306:2022, B50, 50 N load, 50 K/h55–62 °C
    Tensile strength at break, MD, 25 µm cast filmISO 527-3:2018, type 2 specimen, 500 mm/min25–35 MPa
    Elongation at break, MD, 25 µm cast filmISO 527-3:2018, type 2 specimen300–500%
    Elmendorf tear, MD, 25 µm blown filmASTM D1922-23300–600 gf
    Elmendorf tear, TD, 25 µm blown filmASTM D1922-23250–500 gf
    Dart impact F50, 25 µm blown filmISO 7765-1:1988, method A180–320 g

    Tensile data reported in Table 1 were obtained on 25 µm monolayer cast film conditioned at 23 °C and 50% RH for 48 h in accordance with ISO 291:2008. The tensile test used type 2 specimens per ISO 527-3:2018 at a crosshead speed of 500 mm/min. Dart impact F50 values were measured with a 38 mm diameter dart per ISO 7765-1:1988, method A. Blown film lot data show that machine-direction tear is generally 10–25% higher than transverse-direction tear because of orientation effects. The table values are lot-release windows and should not be treated as design minima; downstream draw-down ratio, die gap, and frost-line height can shift elongation and impact by approximately ±30%.

    The thermal analysis profile exhibits a PLA cold-crystallization exotherm between 95–110 °C and a PBAT melting endotherm between 120–130 °C when measured at 20 K/min under ISO 11357-1:2016 and ISO 11357-3:2018. The PLA phase restricts continuous service above 50 °C. Annealing at 80–100 °C for 2 h can increase crystallinity but may embrittle film if quench cooling is not controlled. Dynamic oscillatory data at 180 °C show shear-thinning behavior. The zero-shear viscosity ranges from 800–1500 Pa·s at 0.1 rad/s; at 100 rad/s, the complex viscosity falls to 100–200 Pa·s. This response supports bubble formation at a blow-up ratio of 2.0:1–3.0:1, provided chilled air is used for bubble stabilization.

    When FC 45140 Is Run on a Monolayer Blown Film Line

    Moisture control is the primary processing constraint. The pellets are hygroscopic and can exceed 500 ppm moisture at 23 °C and 60% RH within 8 h. Pre-drying in a desiccant dryer to a dew point of -40 °C is required. The supplier recommends drying at 60 °C for 4 h or 80 °C for 2 h; exposure above 85 °C can cause pellet sintering and feed-throat bridging. Dried pellets should be conveyed with dry air and kept in a hopper purged with nitrogen or dry air. Moisture above 250 ppm causes hydrolysis of the PLA phase, leading to reduced melt viscosity and loss of film impact strength.

    Barrel temperature profile from feed to adapter: 155 °C, 165 °C, 175 °C, 175 °C, 170 °C. Die temperature: 170–175 °C. Die gap: 0.8–1.4 mm. Blow-up ratio: 2.0:1–3.0:1. Frost line height: 2–6 die diameters. The melt temperature must remain within 175–180 °C. At 170 °C, melt pressure increases and surface melt fracture can appear; at 190 °C, the PLA fraction degrades. Continuous residence time at melt temperature should not exceed 10 min. Low-density polyethylene may be used as a start-up purge if the die is cleaned afterward; direct transition from polyvinyl chloride is not permitted because of corrosive decomposition products.

    Cast film processing uses a 0.5–0.8 mm die gap, 170–180 °C die temperature, 25–40 °C polished chill-roll temperature, and 15–40 mm air gap. Chill-roll temperatures below 20 °C increase film curl and blocking. Film thickness between 15–30 µm shows lower haze than blown film but lower transverse-direction tear. Slip and antiblock packages based on fatty acid amides are preferred; amine-based antistatic packages should be avoided because they accelerate hydrolytic chain scission during long runs. In coextruded structures, the grade may be used as a skin layer over PBAT or PHA core, but the melt temperature of FC 45140 should still not exceed 180 °C. A tie layer may be required because the polyester blend has limited adhesion to polyolefins.

    Comparative Performance Against Neat PLA and Starch-Filled PBAT Film Grades

    AttributeFC 45140Neat PLA film gradeStarch-filled PBAT film gradeTest standard
    Melt flow index4.0–7.0 g/10 min3–6 g/10 min5–12 g/10 minISO 1133-1:2022
    Elongation at break, MD, 25 µm film300–500%5–20%500–800%ISO 527-3:2018
    Elmendorf tear, MD300–600 gf10–30 gf200–400 gfASTM D1922-23
    Dart impact F50180–320 g40–80 g250–450 gISO 7765-1:1988
    Vicat softening temperature55–62 °C55–60 °C45–55 °CISO 306:2022
    Equilibrium moisture uptake at 23 °C, 50% RH0.5–1.0 wt%0.3–0.5 wt%2.0–4.0 wt%ISO 62:2008
    Heat seal initiation temperature95–110 °C80–90 °C85–100 °CInternal method; ASTM F88/F88M-23

    Table 2 values are drawn from supplier TDS data for FC 45140 and from published technical datasheets for representative comparison grades. They are not independent test results. FC 45140 occupies a middle position between unmodified PLA and starch-filled PBAT. It retains more stiffness and dead-fold than starch-filled PBAT, while providing much higher elongation and tear resistance than unmodified PLA. The PBAT fraction at 40–50 wt% reduces equilibrium moisture uptake compared with starch-filled grades and avoids granular starch die-lip plate-out. Heat sealing on cast film is typically initiated at 95–110 °C; seal strength reaches 8–12 N/15 mm after 0.5 s dwell at 120 °C when tested according to ASTM F88/F88M-23. This is higher than many neat PBAT-rich grades and closer to PLA, but the seal is not suitable for high-temperature retort applications.

    Operational boundaries are explicit. The compound must not be processed above 190 °C or dried at 85 °C or higher. It should not be combined with amine-based antistatic packages or processed after PVC without thorough purging. Regrind use is limited to 20 wt% unless re-stabilization is performed. Polyolefin contamination above 5 wt% can delaminate and reduce tear strength. Industrial compostability certification of the final article must be confirmed on the finished film thickness and not on the neat compound. Published data for this specific configuration in coextruded barrier structures are limited. Outdoor applications require UV stabilizer addition because both PLA and PBAT undergo photo-oxidative chain scission; for agricultural mulch film, a carbon black or UV masterbatch is necessary at addition levels of 2–6 wt%. The grade is not supplied with slip or antiblock; film converters must add compatible masterbatches to control blocking and coefficient of friction. Storage in unopened moisture-barrier bags at 10–30 °C is recommended; once opened, material should be consumed within 4 h at 50% RH or returned to sealed dry storage.

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