What are Cellulose Plastics?
Cellulose plastics, also known as cellulose-based plastics or cellulosic plastics, are a type of bioplastic that are made partially or fully from plant-based cellulose. Cellulose is a natural polymer that makes up the cell walls of plants and is the most abundant organic polymer on Earth. It can be derived from wood pulp or agricultural waste such as corn stover and sugarcane bagasse. During the manufacturing process, cellulose fibers are broken down into their basic units known as nanocrystals and processed into a plastic-like material that can be molded and shaped.
Applications
Some key applications where these plastics are already being used include:
Packaging Films - Cellulose Plastics are frequently used to produce packaging films for food products. Films made from cellulose plastics are commercially compostable and help reduce plastic waste. Major brands have started using cellulose-based packaging for snacks, fresh produce, frozen foods, and more.
3D Printing Filaments - 3D printing filaments made wholly or partly from cellulose have become increasingly popular in recent years. Being plant-based and compostable, cellulose filaments offer a greener alternative to conventional oil-based plastics used in 3D printing. Various prototyping models, promotional items, and artistic designs are now printed using cellulose filaments.
Textiles - Cellulose fibers derived from wood pulp or agricultural residues can be processed into textile filaments and spun into yarns and fabrics. Brands have brought out clothing lines featuring cellulose blended fabrics that are soft, breathable and biodegradable. These include shirts, pants, dresses and undergarments.
Production Methods
There are a few primary methods used for producing cellulose plastics:
- Microfibrillated Cellulose - This involves separating cellulose fibers into microscopic nanofibrils under high pressure. The nanofibrils are then combined with other biopolymers or plasticizers into a matrix. Popular MFC plastics include films and thermoformed articles.
- Bacterial Cellulose - Certain bacteria like Gluconacetobacter can synthesize pure cellulose strands. When cultured in a solution, they weave an exceptionally strong hydrogel. Removing water yields solid, fiber-reinforced bacterial cellulose sheets suitable for various applications.
- Regenerated Cellulose - Cellulose is dissolved or derivatized before undergoing a regeneration process where it hardens and solidifies. Examples are rayon from cellulose xanthate and cellulose acetates made by esterifying cellulose. These offer plastics-like properties.
- Thermoplastic Processing - Cellulose fibers or pulp are mixed into thermosetting bioplastics or thermoplastic polymers like PLA to impart reinforcement. The resultant composite material can be melted, molded and retains cellulose fiber strength. Extrusion and injection molding are used.
Advantages
The key benefits of using them instead of conventional plastics include:
- Renewable Resource - Cellulose comes from abundant, fast-growing plant biomass and does not depend on finite fossil fuel reserves.
- Biodegradable - Most cellulose plastics fully degrade into carbon dioxide, water and biomass within a few months under natural conditions. This eliminates issues of plastic waste accumulation.
- Carbon Sequestering - As plants absorb carbon dioxide during growth, the locked-up carbon remains sequestered if cellulose is processed into durable products instead of releasing it back as CO2.
- Lighter Environmental Impact - Analysis shows these plastics have lower embodied energy and greenhouse gas emissions than petroleum-based plastics over their lifecycles.
- Compatibility with Existing Infrastructure - Depending on the production method, plastics can be processed on existing plastics manufacturing equipment for molding, film blowing etc. with minor adjustments.
Challenges
While they offer sustainability advantages, there remain some technological and economic challenges slowing their widespread adoption:
- Higher Production Costs - Production costs are currently higher than for conventional plastics largely due to the need for extensive pretreatment of cellulose fibers and lower yields. Economies of scale could help address this.
- Limited Material Properties - They may not match the full range of material properties offered by petro-based plastics. Properties like strength, barrier effects, heat tolerance etc. depend greatly on processing methods.
- Lack of Standardization - There exists variability in formulations, production techniques, certifications and end-of-life management between different cellulose plastics. This creates uncertainty for manufacturers and buyers.
- Slow Adoption in Certain Sectors - Applications in packaging are growing rapidly while sectors reliant on consistent material properties like automotive and electronics are slower to transition due to technological limitations of it.
Though challenges remain, they have immense promise as a sustainable alternative to oil-based plastics due to their renewable resource base and biodegradability. With continued research and commercialization efforts, production costs are expected to go down while material properties improve. As environmental regulations around plastic waste become stricter worldwide, cellulose plastics seem poised to play a key role in the future of plastics manufacturing.
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Ravina Pandya, Content Writer, has a strong foothold in the market research industry. She specializes in writing well-researched articles from different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. (https://www.linkedin.com/in/ravina-pandya-1a3984191)
