SBIR Phase II: Affordable, Scalable, and Compostable Solution for Flexible Plastic Packaging

The broader/commercial impact of this Small Business Innovation Research (SBIR) Phase II project centers on developing a plastic alternative that could transform the $289 billion flexible packaging industry. This innovation addresses critical challenges by replacing conventional plastics responsible for billions of packaging items annually that have less than 5% currently recycled, with a compostable material. This technology uses a bioplastic as a primary ingredient in scalable, home-compostable thermoplastic films, which maintain the strength and barrier properties of conventional plastics. Unlike common terrestrial crops used in bioplastics, this technology requires no arable land or fertilizers, making it an abundant and sustainable resource available on coastlines worldwide. Commercially, this technology enables American plastic manufacturers to seamlessly integrate sustainable alternatives using their current equipment, facilitating rapid industry adoption. Successful commercialization is projected to displace over 1.75 million pounds of plastic waste by 2030. The innovation creates economic opportunities in coastal communities while generating substantial benefits including reduced microplastic pollution. Scientifically, this project advances understanding of marine biopolymer processing, demonstrating how these materials can achieve melt-processability, opening new pathways for sustainable material science. The research contributes valuable knowledge to renewable polymer chemistry and packaging innovation, potentially revolutionizing how society approaches plastic waste. This Small Business Innovation Research (SBIR) Phase II project addresses key scientific challenges in formulating, processing, and scaling novel biopolymer blends for commercial use. The research will develop a tunable thermoplastic system (pellet and film) by modifying composition, processing conditions, and screw design to lower the product cost and improve mechanical properties. The project includes techno-economic and life cycle analyses, pilot-scale testing, end-of-life performance testing, composability testing, and commercialization readiness evaluation. This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.