Manufacturing Cost-Competitive Alternatives to Plastic Via An Innovative Process

This SBIR Phase I project will enable non-meltable, agriculturally derived- polymers to be converted into usable products for the food packaging and commodity products industries. Agriculturally-derived polymers are attractive starting materials because nature produces them. Consequently, chemical synthesis is not required. These agriculturally-derived polymers are also readily available in mass quantities. However, these agricultural feedstocks are non-meltable and cannot be transformed into a viscous melt as is required for traditional injection molding. Therefore, we must look beyond traditional manufacturing methods, and that is the aim of this Phase I proposal. This Phase I proposal's focus on optimized manufacturing will address the critical hurdle in making compostable alternatives to non-biodegradable plastics viable at scale. To manage the variability introduced by the agricultural feedstocks, we will explore advanced statistical process control methods, similar to those used in the food industry, to ensure consistent quality and performance in the final parts.The output will be a validated procedure on a novel machine component that works for non-meltable, agriculturally-derived polymers and can be used in injection-compression molding. We will design and develop the new machine component and processing methodology in-house, and then use them to produce sample products. These will be tested collaboratively with USDA scientists to gather performance data and iteratively refine the design of the new machine component and processing methodology.The development of cost-competitive, compostable alternatives to non-biodegradable plastics could revolutionize society, the economy, and the environment. By reducing dependence on petroleum and cutting down harmful chemical pollution, this technology can help tackle the growing plastic waste crisis. Economically viable compostable replacements offer a solution to the long-lasting damage caused by traditional plastics, decreasing waste in landfills and oceans. A key societal benefit is the reduction in plastic pollution, which lowers exposure to dangerous chemicals like carcinogens and endocrine disruptors, leading to better health and easing strain on healthcare systems. Economically, this technology promises to unlock new markets, create new jobs, and boost rural economies, all while supporting alternative manufacturing and agriculture.