When to Use Biodegradable Film Packaging?

Biodegradable film packaging is ideal when sustainability is a priority, especially for products with short shelf lives. It’s best used for items like fresh produce, baked goods, single-use packaging, or products marketed as eco-friendly. Businesses aiming to reduce environmental impact or meet consumer demand for greener options should consider biodegradable films. However, it's important to ensure proper disposal methods, as some biodegradable materials require industrial composting to break down effectively.

The Role of Biodegradable Films in Sustainable Packaging          

Biodegradable films represent a key innovation in the ongoing effort to reduce plastic waste. BOPP films, traditionally used for packaging in the food and beverage industry, are increasingly being produced with biodegradable additives or fully biodegradable biopolymers, providing a more environmentally friendly alternative to conventional plastic films.

Biodegradable films are designed to break down more quickly than traditional plastic films, either through natural degradation processes or via composting, reducing their environmental footprint. While there are still challenges in scaling production, especially in ensuring performance characteristics like durability, flexibility, and barrier properties, innovations in biopolymer technologies are making these materials more commercially viable.

Technological Advancements and Innovations          

1. PLA-Based Biodegradable Films: Enhancing Barrier Properties

Polylactic Acid (PLA) is one of the most commonly used biodegradable materials in the packaging industry. Derived from renewable resources like corn or sugarcane, PLA is compostable and provides an eco-friendly alternative to petroleum-based plastics. However, one of the biggest limitations of PLA has been its lower barrier properties—an issue when it comes to protecting food products from moisture, oxygen, and light.

Recent innovations in PLA-based films have improved these barrier properties, making them suitable for more demanding applications. By integrating additives such as nanocellulose or nanoclays, manufacturers can enhance PLA films’ performance without compromising their biodegradability. For instance, PLA films with embedded nanocellulose offer improved strength, flexibility, and moisture resistance, making them more suitable for packaging perishable food items.

Moreover, the development of multilayered PLA-based films is addressing many of the performance issues associated with traditional PLA. These films combine PLA with other biodegradable polymers to create a more robust and functional material, which retains its biodegradability but offers improved barrier properties, increased heat resistance, and longer shelf life.

2. PHA-Based BOPP Films: Harnessing the Power of Nature

Polyhydroxyalkanoates (PHA) are biodegradable plastics produced by microorganisms through the fermentation of plant sugars. PHA’s key advantage lies in its superior biodegradability, even in marine environments, where it can break down in a fraction of the time it takes for conventional plastics. In addition, PHA is versatile, offering excellent mechanical properties and resistance to extreme conditions such as temperature fluctuations, humidity, and UV exposure.

The production of PHA has been traditionally expensive due to the complex fermentation processes required to produce it at scale. However, significant progress has been made in reducing production costs through improved fermentation techniques, biotechnology advancements, and scaling up industrial production. Companies such as Newlight Technologies and Danimer Scientific are at the forefront of developing commercial-scale PHA production.

PHA-based films are increasingly used in packaging applications that require biodegradable solutions without sacrificing performance. For instance, food packaging applications—particularly for items like snacks, fresh produce, and beverages—are seeing greater adoption of PHA-based films. Their superior biodegradability and robustness under various environmental conditions make them an ideal alternative to conventional plastic films in these areas.

3. Hybrid and Blended Biodegradable Films: Tailoring Solutions for Specific Needs

The future of biodegradable films lies in the development of hybrid and blended materials that combine the best properties of different biodegradable polymers. These blended films can be engineered to offer specific benefits such as enhanced strength, better moisture and oxygen barriers, and improved thermal stability.

Blending PLA with starch or other biopolymers has resulted in films with superior mechanical properties, making them suitable for more demanding applications like food packaging and even industrial use. These hybrid films are not only biodegradable but also provide performance that matches or even surpasses traditional plastic films in some cases.

4. Nano-Technology and Green Chemistry in Biodegradable Films

Nano-materials are playing an increasingly important role in the development of biodegradable films. Nanocellulose, derived from wood, cotton, or agricultural waste, is one of the most widely researched materials for reinforcing biodegradable films. Its incorporation improves the mechanical strength, flexibility, and barrier properties of the films, helping to extend the shelf life of packaged goods. In addition, nanomaterials such as nanoclays and nanoparticles of metals can enhance the biodegradation process by creating micro-cavities that increase the surface area for microbial attack, speeding up the breakdown of the films.

Green chemistry principles are also driving the development of biodegradable films. By using renewable, non-toxic ingredients and adopting environmentally friendly production processes, companies can create films that have a minimal environmental impact throughout their life cycle. The combination of green chemistry and nanotechnology is paving the way for next-generation biodegradable films that are both high-performance and sustainable.

Market Dynamics and Consumer Perspectives          

Market Trends and Growth Opportunities

The market for biodegradable packaging is growing rapidly, fueled by increasing regulatory pressure, consumer demand for sustainable products, and technological innovations. The global biodegradable films market was valued at approximately USD 1.19 billion in  and is projected to grow at a compound annual growth rate (CAGR) of 7.3%–8.02% over the forecast period, reaching around USD 2.06–2.38 billion by –.  Biodegradable films are expected to capture a significant share due to their versatility and widespread applications in food, beverages, agriculture, and consumer goods.

The food packaging segment is the largest driver of growth in the biodegradable films market. As consumers become more health- and environmentally conscious, there is an increasing demand for eco-friendly food packaging that does not compromise on functionality or freshness. The rise of plant-based and organic food products, which often emphasize sustainability, is contributing to the growing demand for biodegradable films in this segment.

However, the adoption of biodegradable BOPP films is still constrained by the relatively high cost of production compared to conventional plastic films. As production processes scale and raw material costs decrease, the price gap is expected to narrow, making biodegradable films a more attractive option for manufacturers.

Key Players in the Biodegradable Film Market

The biodegradable film market is rapidly evolving, driven by innovation and collaboration among key players aiming to meet the demand for sustainable packaging solutions. Leading companies are leveraging advanced materials, cutting-edge technologies, and strategic partnerships to gain a competitive edge.

• Taghleef Industries: A global leader in specialty films, Taghleef has been actively developing biodegradable BOPP and PLA-based films to meet environmental demands while maintaining high performance.

• Uflex Limited: Known for its innovation in flexible packaging, Uflex offers biodegradable film solutions that cater to the growing demand for sustainable materials in food, pharmaceuticals, and consumer goods.

• Amcor: A packaging giant, Amcor has invested heavily in developing biodegradable films as part of its commitment to achieve 100% recyclable or reusable packaging by .

• BASF: A pioneer in biopolymers, BASF produces Ecovio, a compostable polymer that serves as a base material for various biodegradable film applications.

• Danimer Scientific: Specializing in PHA-based solutions, Danimer focuses on creating biodegradable films that perform well in both industrial and home composting environments.

• Plantic Technologies: Renowned for its bio-based films, Plantic integrates renewable materials and innovative designs to create packaging that balances sustainability with functionality.

These companies are shaping the future of biodegradable films, combining sustainability with market demands. Their efforts are not only driving technological advancements but also influencing regulations and consumer expectations globally.

Biodegradable Films: Types, Applications and Benefits

There has been an increasing interest in the use of biodegradable polymers as an alternative solution to the environmental problems caused by the accumulation of non degradable synthetic containers. 

As a result, much effort has been made to replace plastic films with biodegradable plastic films, an effective measure to solve the plastic film residue pollution.

What are biodegradable films?

Biodegradable films are plastic-based films that have additives included during the manufacturing process. These additives, usually enzymes, enable the plastic to break down.

It can be decomposed by living organisms, such as bacteria or fungi, with or without oxygen without any environmental impact. 

These films can be prepared using proteins, polysaccharides, or lipid materials. Among these innovative strategies is the incorporation of antimicrobial or antioxidants agents in films, which can be used as packaging. These compounds are incorporated into or coated onto food packaging materials to improve food safety and shelf life.

When the biodegradable film breaks down, it turns into smaller pieces of plastic. That is why it requires specific conditions to break down, such as sunlight or certain temperatures to fully biodegrade. 

Types of biodegradable films

Polyethylene will naturally fragment and biodegrade, but it can take many decades to do this, and can in the meantime cause an environmental problem. There are two methods to resolve this problem. One is to modify the carbon chain of polyethylene with an additive to improve its degradability and then its biodegradability. 

The other is to make a film with similar properties to polyethylene from a biodegradable substance such as starch.

Starch-based biodegradable films

Starch-based biodegradable films are made from corn, potatoes or wheat. This form of biodegradable film meets the ASTM standard (American Standard for Testing Materials) and European norm EN for compostability as it degrades at least 90% within 180 days or less under specified conditions.

Examples of polymers with which starch is commonly used

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• Polycaprolactone (PCL)

• Polyvinyl alcohol (PVA)

• Polylactic acid (PLA)

The heat, moisture and aeration in an industrial composting provide the required conditions  for this type of film to biodegrade. 

Pros & cons of starch based film

Pros

• Residual material is biodegradable and compostable. 

• Reduced fossil fuel content (depending on loading of filler)

• Faster degradation of litter

• No net increase of carbon dioxide in the global ecosystem

Cons

• Source of starch can be problematic (competition against food use, rainforests being cleared to grow crops for bioplastics)

• Poorer mechanical strength than additive based – filling a starch bag with wet leaves and placing it curbside can result in the bottom falling out when a haulier picks it up. 

• Degradation in a sealed landfill takes at least six months.

• They have a limited Shelf life.

• Some starch-based film needs to be composted in industrial facilities because the temperature of the compost needs to be at 58C. 

• If mixed with other plastics for recycling, the value of recycling is reduced.

• For plastic recycling, resin identification code 7 is applicable.

Typical applications

• Carrier bag

• Refusal sacks

• Vegetable bags 

• Food films 

• Agricultural films 

• Mailing films 

However, these applications are still very limited compared to those of petroleum-based plastic films.

Additive based biodegradable films

Additives can be added to conventional polymers to make them either oxodegradable or more hydrophilic to facilitate microbial attack.

Oxodegradable

These films are made by incorporating an additive within regular polymers to provide an oxidative and then a biological mechanism to degrade them. This typically takes six months to 1 year in the environment with adequate exposure to oxygen. 

Degradation is a two-stage process; first, the plastic is converted by reaction with oxygen (light, heat or stress accelerates the process) and then these smaller oxidised molecules are biodegraded by naturally occurring microorganisms.

Commercial competitors and their trade associations allege that the process of biodegradation stops at a certain point, leaving fragments, but they have never established why or at what point. 

OXO-degradation of polymer material has been studied in depth at the Technical Research Institute of Sweden and the Swedish University of Agricultural Sciences. A peer-reviewed report of the work showed 91% biodegradation in a soil environment within 24 months, when tested in accordance with ISO .

OXO-degradation has been studied at the Eurofins laboratory in Spain, where on 25 July  they noted 88.9% biodegradation in 121 days. 

The EU has however disputed the statements about biodegradation of oxo-degradable plastics. In a  report, it was stated that the biodegradation of the fragmented pieces is only partially supported.

Enhancing hydrophilicity of the polymer

These films are inherently biodegradable over a long period. Enhancement of biodegradability of the polymer by adding in additives to change the hydrophobic nature of the resin to slightly hydrophilic allows microorganisms to consume the macromolecules of the product.

Enhancing the hydrophilicity of the polymer allows fungus and bacteria to consume the polymer at a faster rate utilising the carbon inside the polymer chain for energy. These additives attract certain microorganisms found in nature.

Pros and cons of additive based film

Pros

• Much cheaper than starch-based plastics.

• Can be made with standard machinery, and can be used in high-speed machines.

• Materials are well known.

• Does not compete against food production.

• These films look, act and perform just like non-degradable counterparts, during their service-life but then break down if discarded.

• They can be recycled with regular plastics.

• Like regular plastics, they are made from a by-product of oil or natural gas.

• They are certified non-toxic, and safe for food-contact.

Cons

• Degradation depends on access to air.

• They are not designed to degrade in landfill. 

• European (EN) or American (D) Standards on compostable products are not appropriate, as they are not designed for composting. They should be tested according to ASTM D.

• They are not suitable for Polyethylene Terephthalate (PET) or Polyvinyl Chloride (PVC).

• The precise rate of degradation/biodegradation cannot be predicted.

Benefits of biodegradable films

Biodegradable films are material that will decompose naturally when introduced in the environment. The end result of biodegradable films is less harmful to the environment as compared to regular plastic bags.

• Reduction in Carbon Emission

One of the main benefits of using biodegradable films is a significant reduction in the carbon emissions that happen during the manufacturing process. Not just that, since the materials used to create biodegradable films are plant-based, minimal carbon is emitted during the composting process.

• Lesser Energy Consumption

While the initial investment might be slightly higher, in the long run, biodegradable films require lesser amounts of energy.

• Eco-Friendly Disposable Solution

Biodegradable films require composting or recycling to ensure proper breakdown of the plastic pieces to enable the natural composting process.

• Recyclable Material

Apart from taking a significantly lesser time to breakdown as compared to regular plastic, biodegradable films can also be further recycled to create more plastic by-products.

• Lower Petroleum Consumption

Oil is a significant ingredient in the manufacturing of traditional plastics. Petroleum is known to have negative impacts on the environment. Biodegradable plastics use natural products; therefore, the use of bioplastic can profoundly reduce the amount of petroleum used and consequently lessen its environmental hazards.

Applications of biodegradable films

• Food Industry: In the last decade, there has been an increased interest from the food, packaging and distribution industry toward the development and application of bioplastics for food. Applications of biodegradable films in the food industry include; edible coating, paper boards, egg trays, carry bags, wrapping films and food packaging.

• Agriculture : The use of biodegradable films for soil mulching and low tunnel covering is seen as a sustainable solution for the disposal and management of agricultural plastic waste.  Furthermore, there is no indication of ecotoxicity or reduced soil quality from using biodegradable films.

• Cosmetic & Personal Care Products Packaging: Much of the conversation around environmental sustainability in the beauty industry is about post-consumer packaging waste to which only biodegradability seems to be a feasible way of managing post-consumer product waste.  Idealpak, an ISO : certified manufacturer of primary packaging for cosmetics and personal care industry, offers biodegradable packaging.

• Hospital food service ware: Disposable food service ware is widely used in hospitals. Disposable products provide some benefits to hospitals – ease of use, minimal maintenance and reduced dishwashing needs.

Currently, biodegradable alternatives exist that can reduce human and environmental health degradation. Biodegradable food service ware is made from a renewable resource and can be composted at end life. It also doesn’t leach chemicals during use.

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