Dordan exhibits ‘first’ thermoformed algae-plastic

7 November 2012


At Pack Expo in Chicago, October, the Dordan Manufacturing Company introduced the “first ever” thermoformed sample of an algae-plastic compound, using material supplied by specialist manufacturer Algix.

Dordan, a US-based supplier of custom designed thermoformed packaging solutions, was first approached by Algix at Pack Expo in 2011, as a result of Dordan’s ‘Bio Resin Show N Tell’ exhibit, which consisted of various biobased, biodegradable or compostable resins with associated specs and environmental profiles.

“To date, few bioresins have met the economic and performance requirements of our clients,” says Dordan CEO and president Daniel Slavin. “We are excited about the potential of Algix’s algae-plastic because it uses industrial waste, as opposed to agricultural by-products, as feedstock.

“Consequently, the debate over using agricultural land to produce the components necessary to synthesise the PLAs and PHAs of the world doesn’t apply, as this technology literally converts waste to biomass.”

Located in the state of Georgia, home to more than 150 carpet plants that produce millions of gallons of nutrient-rich waste water, Algix has partnered with the University of Georgia and Kimberly-Clark to commercialise the cultivation of aquatic biomass, such as algae, as a feedstock for bioplastic conversion.

The bioresins from Algix are produced using feedstock derived up to 70% from aquatic biomass obtained from nitrogen and phosphorus-rich wastewater, blended with various concentrations of PE, PP, EVA, PLA, TPS, PHA etc, for use in a wide range of end-use applications.

Through bioremediation using algae and aquatic macrophytes, photosynthesis captures solar energy and converts the waste water nutrients into biomass that can be used as raw material for composite formulations to make bioplastics.

Dordan reports that it was able to successfully thermoform algae-PP sheets from Algix over a sample mould at the first attempt, and that it behaved in a similar way to other blended resins such as PP + calcium carbonate.

Algix says its approach can allow certain industries the opportunity to capture their lowest-value waste product. Given further development and investment, the material “may be a viable option for those looking for a cost-competitive, bio-based, and thermoformable resin”, Dordan says.




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