Seeking Biodegradable Thermoplastic Resin for Injection Molding

Background

Polyolefins, such as polyethylene (PE) and polypropylene (PP), are widely utilized in injection molded packaging due to their favorable properties. These thermoplastics offer advantages like low cost, chemical resistance, durability, and ease of processing, making them suitable for various applications, including rigid containers, threads, and closures. Despite their widespread use, most polyolefins are derived from petrochemicals and are resistant to biodegradation, leading to long-term persistence in the environment and growing concerns around plastic waste and pollution. Various biodegradable and compostable materials, such as polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), polyhydroxyalkanoates (PHA), and thermoplastic starch (TPS) blends, have been explored as alternatives to traditional polyolefins. However, many of these materials lack the mechanical strength or processability required for injection molding applications. Moreover, some have densities greater than 1 g/cm3, which causes them to sink in water and hinders separation in recycling systems that rely on flotation to isolate polyolefins. This density mismatch is particularly problematic in fiber-based packaging formats, where plastic closures must float during paper repulping for efficient separation from the fiber stream, and in some cases, must also be compatible with PET bottle recycling processes. Developing a resin with a density below 1 g/cm3 that can be formed into injection-molded closures and other primary packaging components would address both the mechanical and recycling-level requirements for fiber-based packaging combinations. Such material would support PepsiCo's sustainability goals by reducing reliance on fossil-based plastics, minimizing environmental impact, meeting corporate targets, complying with regulations, and addressing consumer demand for eco-friendly packaging.

Key Success Criteria

Must-Haves

• Exhibit a density of less than 1 g/cm3
• Compatible with fiber repulping and/or PET recycling systems
• Thermoplastic behavior with melt-flow index of 25–55 (ASTM D1238), compatible with PE/PP injection molding grades
• Compliant or showing a clear path to compliance with direct food-contact regulations
• Technology readiness levels (TRL): 2-9

Nice-to-Haves

• Derived fully or partially from renewable feedstocks
• Compostable at home or biodegradable in soil; industrial or marine degradation is a plus

Possible Approaches

• Bio-based polyester variants (e.g., polybutylene succinate (PBS) or polybutylene adipate terephthalate (PBAT)) with engineered density
• Polyhydroxyalkanoate (PHA) composites
• Polylactic acid- (PLA-) based blends
• Thermoplastic starch (TPS) formulations with reduced density
• Low-density biodegradable polymers, composites, or filled systems
• Resins with physical or chemical foaming capability

Approaches not of interest

• Materials that break down into toxic components under its intended end-of-life scenario
• Bio-based polyolefins with no biodegradability

Preferred Collaboration types

• Sponsored Research
• Co-development

Additional Information

• Research Funding is proposal dependent and typically ranges from $25,000 to $100,000. Preference will be given to an integrated team that has all of the capabilities needed to develop the model.
• PepsiCo will provide access to various tools and technologies to test spray coatings and conduct barrier testing.
• Work directly with PepsiCo's team of scientists and engineers with deep experience in material science, packaging, and bringing new products to market at massive scale.