[Virtual Presenter] Good morning everyone and welcome to our meeting on the project on compostable forks. We are excited to present to you our initiative to develop special compounds for foldable forks that meet all compostability requirements. Our team has been working hard to ensure that our forks are not only environmentally friendly but also meet the highest standards of durability and functionality. We are using Polyhyroxyalkanates (P-H-A--) Polylactic acids (P-L-A--) Polybutylenesuccinate (P-B-S--) and Polycaprolactone (P-C-L--) as key compostable polymers. We will cover commercial mold development cost. We hope you find this presentation informative and look forward to your feedback.. 

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A SSF Plastics India Pvt. Ltd. Initiative
Innovation  Program - 2024

[Audio] We will examine several combinations of biodegradable materials to determine the best processing conditions for producing a compostable fork. The main objective of this project is to ensure that the component generated adheres to the established international standard of composability. We believe that this project will make a significant contribution to the reduction of plastic waste in our environment.. 

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Examine several combinations of biodegradable materials to determine the best processing conditions for producing the required component. Make sure that the component generated adhere to the established international standard of composability.

[Audio] Biodegradable and compostable plastic are two different types of plastic. Biodegradable plastic breaks down through the action of living organisms usually microbes. However if left in a natural environment it often only breaks down into micro-plastics which can create ‘plastic smog’ in parts of the ocean and accumulate in soils. Compostable plastic on the other hand is a term that refers to any product that can break down into a nutrient-rich soil amendment through the process of composting. The key factor is that compostable products do not have any toxic elements to the environment after degradation.. 

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Biodegradable plastic is plastic that will break down through the action of living organisms, usually microbes. To fully break down, biodegradable plastics require the right environment, which usually means commercial processing. If biodegradable plastic is left to break down in a natural environment – such as in landfills or the sea – it often only breaks down into micro-plastics. These micro-plastics can create ‘plastic smog’ in parts of the ocean and accumulate in soils.

Compostability is a broader term than biodegradation, all compostable products biodegrade but not all biodegradable products are compostable. The key factor is that compostable products do not have any toxic element to the environment after degradation. A product that is biodegradable under composting conditions is not necessarily compostable, as the material characteristics, timely disintegration, and ecotoxicity must also be verified for full proof of compostability.

[Audio] Our mini fork measuring 16 centimeters x 8 centimeters has a monthly requirement of 10 lacs while our regular fork measuring 18 centimeters x 9 centimeters requires 20 lacs per month. We are focused on meeting the heat resistance requirements of up to 90 degrees which we achieve by combining two polymers to create a product that is both heat-resistant and compostable. Indo Nissan has agreed to cover the commercial mold development cost.. 

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Developing special compounds which are meeting all that compostablity requirement. Fortunately, we are now started working with the key cuppa noodles supplier indo-Nissan, who has requested for the foldable fork to be developed in two different sizes. The monthly requirement for mini fork is 10 lacs & regular fork is 20 lacs. There critical requirement is to meet heat resistance upto 90 degrees. For that, we are working with two different compounding suppliers who are going to combine two polymers to achieve heat resistance & compostability requirements. We are going to come up with a bounce that we are meeting all the requirements from both functional point of view & compostability point of view. Indo Nissan has confirmed that they will cover commercial mould development cost.

[Audio] These key compostable polymers are essential in the production of compostable forks. They are biodegradable have several advantages and are widely used in the production of consumer products. We are here to discuss the importance of compostable forks and how these key compostable polymers contribute to their production. Please feel free to ask any questions you may have.. 

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POLYHYDROXYALKANOATES (PHA) - Polyhydroxyalkanoates (PHA) is a plastic resin produced by bacteria taking action on sugars or lipids. Various molecules are combined, and the subsequent plastic resin has many different properties that benefit injection molding the environment. PHAs can withstand UV exposure without degradation, do not change when exposed to moisture, nor they do not absorb odors.  These resisting qualities make them a perfect option for food packaging, cosmetic products, and some medical devices likes surgical mesh and sutures.
 POLYLACTIC ACIDS (PLA) -  Polylactic acids (PLA) are made from tapioca, cassava, sugarcane, or cornstarch. PLAs are used in manufacturing a large number of consumer products, such as medical implant rods and screws.  PLAs are also used widely in one-time use cups, disposable food packaging, and one-time use utensils.
 POLYBUTYLENE SUCCINATE (PBS) - Polybutylene succinate (PBS) is an aliphatic polyester with characteristics comparable to polypropylene.  One major difference is that PBS will degrade naturally and result in water and CO2 being introduced into the environment. PBS is made from succinic acid, which is an organic chemical common to most living organisms. PBS is frequently used in food packaging, packaging for cosmetic products, medical implants, and dissolvable drug encapsulation. PBS is also often blended with Polyactic acids (PLAs) to modify characteristics concerning strength and impact resistance without changing affecting thermal or tensile properties.
 POLYCAPROLACTONE (PCL) - Polycaprolactone (PCL) is commonly added in the production of polyurethanes to increase impact resistance and improve water, oil, solvents, and chemical resistance. It is derived from vegetable oils and frequently mixed with starch-based plastics (such as TPS) to decrease material cost or to adjust tensile characteristics of a particular material. PCLs are typically used in dissolvable drug delivery systems, dissolvable sutures after medical procedures, and other medical products to aid in tissue repair.

[Audio] On slide six we will be discussing the tests that ensure the quality and safety of our compostable forks. The presentation is an initiative by S-S-F Plastics India Pvt. Ltd. as part of their Innovation Program for 2024. The biodegradation test is an important test that ensures the material is being broken down by naturally occurring microbes like bacteria fungi and algae. The test is conducted by measuring the cumulative C-O-2 respired by the microbes as they consume the material. The standard test temperature is 58 ± 2℃ and the test must be conducted for 6 months. The sample must degrade at least 90% of the starting carbon to pass the test. The chemical characterisation test is another important test that ensures the materials do not contain unacceptable levels of heavy metals and other toxic components. Generally these standards require fluorine and heavy metal testing (for example zinc copper nickel cadmium lead mercury chromium molybdenum selenium arsenic). Specific limits are included in the standard or depend on the country the material will be sold and/or composted in. There is also a requirement for the sample to contain at least 50% volatile solids.. 

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Biodegradation test - Ensures that the material is being broken down by naturally occurring microbes like bacteria, fungi and algae. This is achieved by measuring the cumulative CO2 respired by the microbes as they consume the material.







 Chemical characterisation test - Ensures that the materials do not contain unacceptable levels of heavy metals and other toxic components. Generally, these standards all require fluorine and heavy metal testing (e.g. zinc, copper, nickel, cadmium, lead, mercury, chromium, molybdenum, selenium, arsenic). Specific limits are included in the standard or depend on the country the material will be sold and/or composted in. There is also a requirement for the sample to contain at least 50% volatile solids.

Standard Test temperature Time Pass criteria Industrial Composting 58 ± 2℃ 6 months Sample must have degraded at least 90% of the starting carbon Home composting  25 ± 2℃ 12 months Mass or alternatively at least 90% biodegradation relative to the cellulose control.

[Audio] Discuss tests. Disintegration test. Biodegradable. Harmless compounds. Ecotoxicity test. Impact on environment. Standards for industrial and home composting. Temperature time dry weight criteria for disintegration test. Important to note. Standards used to ensure compost safe and high-quality. Summary. These tests crucial for ensuring compostable fork safe and high-quality compost.. 

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Disintegration test - Ensures that the material reduces to a defined size within a fixed time to be considered a part of the compost.












 Ecotoxicity test - Ensures that the degraded material will not affect the compost quality and thus plant growth and soil ecosystem health. All the standards use the compost from disintegration to compare seedling germination and growth to a control compost. The test compost germination rate and biomass weight has to be no less than 90% of seedlings from the control compost to pass. The Australian standards also includes a worm test where no more than 10% in morbidity or weight difference between the test compost and the control is allowed.

Standard Test temperature Time Pass criteria Industrial composting Max temp remains below 75℃ during the first week and below 65℃ for the following weeks. Temperature is above 60℃ for at least 1 week, above 40℃ for at least 4 consecutive weeks. 84 days No more than 10% of the sample dry weight remains after sieving with a 2mm sieve. Home composting 25 ± 2℃
 180 days

[Audio] Discuss compostable fork project.. Key critical Requirements. 

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Machine – The small barrel size will be favorable for this material, Screws can be made wider to avoid shearing, dehumidifier/hopper dryer. Mould – Air venting in the mould for quality product, gates can be made shear sensitive.  Load bearing – The component should hold the weight according to the application. e.g. the fork should hold the weight of 50g to 60g. Foldability/flexibility – While doing development in spoon, fork, spatulas the component should have flexibility. Drop test – The component should pass drop test like10 drops from 5 feet. Heat resistance – The component should servive temperature upto 90 degrees. Composting system – Many biodegradable plastics are designed to degrade in industrial composting systems. However, this requires a well-managed waste system to ensure that this actually happens. If products made from these plastics are discarded into conventional waste streams such as landfill, or find their way into the open environment such as rivers and oceans, potential environmental benefits are not realised and evidence indicates that this can actually worsen, rather than reduce, the problem of plastic pollution.

[Audio] We are conducting a load bearing test on the compostable fork. This test is crucial in determining the weight the fork can hold. The fork must be capable of bearing a weight of 50 grams to 60 grams.. 

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Load Bearing Test - The fork should hold weight of 50g  to 60g Sun Light Exposure Test –fork to be kept in sunlight for 6 hrs for observation. Foldability Test - The fork must withstand 500 opening and closures Drop Test - 10 drops from 5 feet Heat Resistance Test/Hot Water Boiling Test - Fork should survive temperatures up to 90 degrees FTIR/DSC Deformation Test
 Note – The functional tests have been established based on the key critical requirements.

A hand holding a spoon with noodles

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[image] A group of forks in a bowl Description automatically generated

[Audio] Our project on compostable forks is currently progressing. Indo Nissan has given us a lead and wants to work with us to develop compostable forks. We have now sourced the material from two compounding suppliers: Rajiv plastics and Konspec. Rajiv plastics is combining two polymers (PLA & P-B-S--) to achieve the necessary requirements while Konspec is achieving the requirements through crystallization in P-L-A material. We have conducted trials with Konspec material on one of our pilot molds that we have developed for Nestle. The results were good and we achieved heat resistance. We submitted these samples to Indo Nissan to get their approval on design and functions. The pilot tool will be used for preliminary trials to determine the compostability criteria. After we accomplish the essential conditions as specified by Indo Nissan we can proceed with the commercial mold. However we are still waiting for the material from Rajiv plastics which we expect to receive on June 24 2024.. 

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Fortunately, Indo Nissan gave us a lead and wants to work with us to develop compostable forks. We are now sourcing the material from two compounding suppliers that are Rajiv plastics & Konspec. Rajiv plastics going to combine two polymers (PLA & PBS) to achieve necessary requirements & Konspec will achieve the requirement through crystallization in PLA material.  We have done trial with Konspec material on one of the pilot mould we are having which we have developed for nestle. In one of our design, results were good, and heat resistance also achieved. We submitted those samples to Indo-Nissin to get their approval on design & functions also. The pilot tool will be used for preliminary trials in order to dermine the compostibility criteria.   After we accomplish the essential conditions as specified by Indo Nissan, we can proceed with the commercial mould. The material from rajiv plastics has not yet received. We are expecting the material on June 24, 2024

[Audio] We initiated the program as a S-S-F Plastics India Pvt. Ltd. initiative as part of our Innovation Program for 2024. In our trial we started with 100% bio-compound with a barrel temperature range of 180 to 200 degrees and a tip temperature minimum of 175 to 210 degrees and a cooling temperature of 25 seconds (suggested by Konspec). We encountered issues with cracking and part catching. In the second trial we added a bio-degradable additive provided by Konspec which resolved the cracking issue. However the ejection or product catching issue still persisted. We also sprayed part release spray in the mould but after running for 45 to 60 minutes the issue was again occurring. We added an additive of 5% to check the results but the issue was still there. Despite finding the product good there was an issue in continuous run. We conducted a heat resistance test on the produced samples and found them okay. We are currently waiting for feedback from Indo-Nissin and coordinating with Konspec to overcome the processing and part catching issues.. 

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Initially we started trial with 100% bio-compound with barrel temperature range 180 to 200 degrees and tip temperature minimum 175 to 210 & cooling temperature 25 sec (As suggested by Konspec). In this trial part was catching & cracking was happening.  In 2nd trial we added bio-degradable additive provided by konspec about 2-3%, in this case cracking issue was solved (in some areas material spread impression was there, but it was also controlled in processing later on)  but ejection that means product catching issue was still there. We were also spraying part release spray in mould but after running 45 mins to 60 mins properly the issue was again occurring.  We have also added additive to 5% just to check what are the results but the issue was still there.  Product found good but there was issue in continues run.  I have done heat resistance test on the produced samples and found okay. We are waiting for the feedback from Indo-Nissin. In the meantime, we are also co-ordinating with Konspec to overcome this processing/part catching issue.

[Audio] We are waiting for the arrival of Rajiv Plastics’ material and Indo-Nissin’s compostable polymer. Once we receive feedback from Indo-Nissin regarding the samples we sent them we can proceed with the commercial mold if they approve our design (fork without hinge – 2 pc). If not we will need to develop a new pilot mold of fork with hinge. We will send the most promising samples from all three trials to Chennai C-I-P-E-T for Compostability testing. Once we validate the pilot tool trials with Indo-Nissin and find that our product passes the critical requirements we will proceed with making a commercial tool. Indo-Nissin has confirmed their investment in the commercial mold. We are excited about the progress we have made and look forward to bringing our compostable fork to market soon.. 

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To conduct more trials, we are waiting for Rajiv plastics’ material. Indo-Nissin is also providing international grade of compostable polymer which we are also planning to trial.  After getting feedback from Indo-Nissin regarding the samples we sent them. We can move on with the commercial mould if they approve our design (fork without hinge – 2 pc). If not, we will need to develop another pilot mould of fork with hinge. We will send the most promising samples from all three trials (for material finalization) to Chennai CIPET for Compostibility testing.  Once we completed the validation of pilot tool trials with Indo Nissan and found that our product passes critical requirements then we are going ahead and making commercial tool. Indo Nissan has confirmed that they will invest in the commercial mould.

[Audio] Regular foldable forks from Indo-Nissin Mini foldable forks from Indo-Nissin Per kg compostable material cost from Konspec which is Rs. 346/Kg.. 

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We received the existing samples of regular & mini foldable fork from Indo-Nissin (RM – PP).  Konspec also shared per kg compostable material cost which is Rs. 346/Kg Below is an estimated price for foldable forks based on the points mentioned.

Fork Size Weight  Estimated Cost (Rs.) Target cost (Rs.)  Regular Fork 2.5 g 1.70 to 1.80 1.60 Mini Fork  1.9 g 1.40 to 1.50 1.40

A close-up of several forks

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A close-up of a white plastic fork

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PROJECT ON COMPOSTABLE FORK

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We will examine several combinations of biodegradable materials to determine the best processing conditions for producing a compostable fork. The main objective of this project is to ensure that the component generated adheres to the established international standard of composability. We believe that this project will make a significant contribution to the reduction of plastic waste in our environment.

avatar

Biodegradable and compostable plastic are two different types of plastic. Biodegradable plastic breaks down through the action of living organisms
 usually microbes. However
 if left in a natural environment
 it often only breaks down into micro-plastics
 which can create ‘plastic smog’ in parts of the ocean and accumulate in soils. Compostable plastic
 on the other hand
 is a term that refers to any product that can break down into a nutrient-rich soil amendment through the process of composting. The key factor is that compostable products do not have any toxic elements to the environment after degradation.

Our mini fork
 measuring 16  centimeters x 8  centimeters
 has a monthly requirement of 10 lacs
 while our regular fork
 measuring 18  centimeters x 9  centimeters
 requires 20 lacs per month. We are focused on meeting the heat resistance requirements of up to 90 degrees
 which we achieve by combining two polymers to create a product that is both heat-resistant and compostable. Indo Nissan has agreed to cover the commercial mold development cost.

These key compostable polymers are essential in the production of compostable forks. They are biodegradable
 have several advantages
 and are widely used in the production of consumer products. We are here to discuss the importance of compostable forks and how these key compostable polymers contribute to their production. Please feel free to ask any questions you may have.

On slide six
 we will be discussing the tests that ensure the quality and safety of our compostable forks. The presentation is an initiative by S-S-F Plastics India Pvt. Ltd. as part of their Innovation Program for 2024.
                                    
                                    The biodegradation test is an important test that ensures the material is being broken down by naturally occurring microbes like bacteria
 fungi and algae. The test is conducted by measuring the cumulative C-O-2 respired by the microbes as they consume the material. The standard test temperature is 58 ± 2℃ and the test must be conducted for 6 months. The sample must degrade at least 90% of the starting carbon to pass the test.
                                    
                                    The chemical characterisation test is another important test that ensures the materials do not contain unacceptable levels of heavy metals and other toxic components. Generally
 these standards require fluorine and heavy metal testing (for example zinc
 copper
 nickel
 cadmium
 lead
 mercury
 chromium
 molybdenum
 selenium
 arsenic). Specific limits are included in the standard or depend on the country the material will be sold and/or composted in. There is also a requirement for the sample to contain at least 50% volatile solids.

Discuss tests. Disintegration test. Biodegradable. Harmless compounds. Ecotoxicity test. Impact on environment. Standards for industrial and home composting. Temperature
 time
 dry weight criteria for disintegration test. Important to note. Standards used to ensure compost safe and high-quality. Summary. These tests crucial for ensuring compostable fork safe and high-quality compost.

We are conducting a load bearing test on the compostable fork. This test is crucial in determining the weight the fork can hold. The fork must be capable of bearing a weight of 50 grams to 60 grams.

Our project on compostable forks is currently progressing. Indo Nissan has given us a lead and wants to work with us to develop compostable forks. We have now sourced the material from two compounding suppliers: Rajiv plastics and Konspec. Rajiv plastics is combining two polymers (PLA & P-B-S--) to achieve the necessary requirements
 while Konspec is achieving the requirements through crystallization in P-L-A material. We have conducted trials with Konspec material on one of our pilot molds that we have developed for Nestle. The results were good
 and we achieved heat resistance. We submitted these samples to Indo Nissan to get their approval on design and functions. The pilot tool will be used for preliminary trials to determine the compostability criteria. After we accomplish the essential conditions as specified by Indo Nissan
 we can proceed with the commercial mold. However
 we are still waiting for the material from Rajiv plastics
 which we expect to receive on June 24
 2024.

We initiated the program as a S-S-F Plastics India Pvt. Ltd. initiative as part of our Innovation Program for 2024. In our trial
 we started with 100% bio-compound with a barrel temperature range of 180 to 200 degrees and a tip temperature minimum of 175 to 210 degrees and a cooling temperature of 25 seconds (suggested by Konspec). We encountered issues with cracking and part catching. In the second trial
 we added a bio-degradable additive provided by Konspec
 which resolved the cracking issue. However
 the ejection or product catching issue still persisted. We also sprayed part release spray in the mould
 but after running for 45 to 60 minutes
 the issue was again occurring. We added an additive of 5% to check the results
 but the issue was still there. Despite finding the product good
 there was an issue in continuous run. We conducted a heat resistance test on the produced samples and found them okay. We are currently waiting for feedback from Indo-Nissin and coordinating with Konspec to overcome the processing and part catching issues.

We are waiting for the arrival of Rajiv Plastics’ material and Indo-Nissin’s compostable polymer. Once we receive feedback from Indo-Nissin regarding the samples we sent them
 we can proceed with the commercial mold if they approve our design (fork without hinge – 2 pc). If not
 we will need to develop a new pilot mold of fork with hinge. We will send the most promising samples from all three trials to Chennai C-I-P-E-T for Compostability testing. Once we validate the pilot tool trials with Indo-Nissin and find that our product passes the critical requirements
 we will proceed with making a commercial tool. Indo-Nissin has confirmed their investment in the commercial mold. We are excited about the progress we have made and look forward to bringing our compostable fork to market soon.

Regular foldable forks from Indo-Nissin 
                                     Mini foldable forks from Indo-Nissin 
                                     Per kg compostable material cost from Konspec which is Rs. 346/Kg.