Fully compostable impact-modified PLA foam for sustainable disposable packaging
Compostable PLA foam technology combining high impact strength (up to 350 J/m), tensile strength (900 MPa modulus), and heat resistance (>100°C) for disposable cup and packaging applications. Built on soybean oil-based co-extrudate additives compatible with standard extrusion processes.
Overview
This solution offers a fully compostable, impact-modified PLA foam technology designed to meet the performance requirements of disposable cups and similar packaging applications. Developed through a soybean oil-based co-extrudate system compounded with Ingeo PLA resins, the technology delivers an unusual combination of mechanical toughness, extensibility, and thermal resistance for a bioplastic material. The formulations are designed to be processed using standard industrial methods, enabling converters and manufacturers to adopt sustainable alternatives without major equipment changes.
The core value proposition is enabling compostable packaging that does not compromise on the durability, impact performance, or heat resistance typically expected from conventional plastics. Target applications include disposable cups, food service packaging, and other single-use items where both regulatory compostability and mechanical performance are required.
Technical specifications
Key features:
- Soybean oil-based co-extrudate additive compounded with Ingeo PLA resins
- Elastic modulus of approximately 900 MPa, providing structural rigidity
- Elongation-to-break of up to 350%, supporting extensibility and forming
- Impact strength up to 350 J/m, enabling high-performance impact modification
- Heat distortion temperature exceeding 100°C with proper crystallization management
- Designed to meet ASTM D6400 compostability standards
- Compatible with twin-screw compounding, extrusion, and injection molding processes
- Foamable formulation intended for foam extrusion processing
Technology readiness level
The technology has been validated at the lab scale, with multiple formulations compounded and evaluated for thermal and mechanical properties, including tensile and impact performance. Current work focuses on adjusting formulations to meet specific partner material requirements, followed by scale-up to several kilograms for foam extrusion trials. Next steps include FDA and compostability certification, and transfer of candidate foams to partners for prototyping of disposable cup applications.
About Saber Chemical, Inc.
Saber Chemical, Inc. specializes in the development and commercialization of compostable core-shell particles (CCSPs) designed to enhance the performance of bioplastics. By integrating these CCSPs into materials such as PLA, PHA, PBS, PBT, PBAT, TPS, and PCL, the company produces performance-grade pellets that offer increased toughness, often achieving greater than 200 J/m Izod impact strength, while maintaining ASTM D6400 compostability. This technology, which originated from NSF-funded research, utilizes glycerol-ketal acrylates to create nanoscale particles that improve material properties without sacrificing environmental sustainability. The company's innovations are designed to be compatible with standard industrial manufacturing processes, including twin-screw compounding, extrusion, and injection molding.
These solutions are targeted at converters and manufacturers in sectors such as packaging, consumer goods, agricultural films, and medical devices who require high-performance, sustainable material alternatives. By providing a scalable approach to material modification, Saber Chemical assists partners in developing durable, compostable products that meet demanding mechanical and thermal requirements. The company engages with customers through technical data support, sample requests, and collaborative research and development efforts, leveraging expertise in polymer chemistry and sustainable monomer synthesis to facilitate the adoption of its additives in commercial applications.
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