Starch based thermoplastic resin for injection molding

Overview

Cruz Foam's innovative starch-based thermoplastic resin is designed specifically for injection molding applications, offering a sustainable alternative to traditional petroleum-based plastics. Derived from upcycled starch and chitin, this resin meets the stringent performance, processing, and shelf-life requirements necessary for food and beverage packaging. It is fully compostable at the end of its life cycle, supporting circular packaging commitments while maintaining commercial scalability. This solution seamlessly integrates into existing injection molding equipment without significant retooling, delivering the necessary strength, flexibility, and barrier properties demanded by industry leaders such as Pepsi.

Technical specifications

The resin formulation combines polylactic acid (PLA) with biodegradable synthetic polymers such as PBS or PBAT, enhanced by Cruz Foam's chitin binder. This results in a low-density material (≤ 0.98 g/cm³) that maintains the mechanical integrity required for packaging applications. The resin has been engineered to ensure compatibility with standard injection molding processes, including specific drying specifications, barrel temperatures, and back pressure settings. Additionally, it offers solid skin with foamed core parts, meeting ASTM testing standards for density, tensile strength, impact resistance, and more. Importantly, the resin supports mechanical recycling with regrind capabilities up to 20%.

Technology readiness level

Currently at Technology Readiness Level 3, the resin has undergone initial formulation screening and property validation. Future phases include extensive process trials and regulatory compliance checks for food contact materials. The final phase focuses on scaling up production, including pilot pelletizing and injection molding trials, to lock in specifications and cost structures.