FIELD OF THE INVENTION:

The present invention herein belongs to a packaging material, particularly relates to a biodegradable packaging container, or referred as a bag material made using a plurality of sustainable materials which can replace usage of non-biodegradable materials, more particularly methods of preparing the package container constituted with a plurality of layers to confirm the freshness and as a logistical solution for a plurality of chemicals, for instances fertilizer and pesticide items.

BACKGROUND OF INVENTION:

There exists a plethora of problems in the field of fertilizer industry where in the material used for the packing is of non-biodegradable which is mainly of plastic. These problems have a serious impact on environment. This needs to be replaced with a sustainable, biodegradable, and ecofriendly materials. According to the United Nations Environment Programme (UNEP), the world produces around 300 million tons of plastic waste each year. Approximately 50% of this plastic is for single -use purposes, such as packaging. It is estimated that by 2050, there will be more plastic in the ocean than fish, by weight. Plastic waste has also been found in 100% of marine turtles, 59% of whales, 36% of seals, and 40% of seabird species examined.

In the fertilizer industry, plastic packaging is commonly used due to its durability and costeffectiveness. However, plastic packaging accounts for a significant portion of plastic waste globally. According to the European Bioplastics, the global bioplastics production capacity reached 2.11 million tonnes in 2019, and it is projected to grow to 2.44 million tonnes by 2024.

Therefore, there is a pressing need to transition from non-biodegradable plastic packaging to sustainable, biodegradable, and eco-friendly materials in the fertilizer industry. By doing so, the industry can help reduce plastic waste and its harmful impact on the environment. Additionally, it can support the shift towards a circular economy, where materials are reused and recycled, reducing waste and conserving resources. W02022175700A1 relates to a biodegradable raw material containing chaff and PLA that is suitable for the production of containers.

WO2013182757A1 discloses packaging material that contains base paper that comprises cellulose-containing natural fibres and a binding agent, at least one biopolymer, the packaging material.

WO2022152867A1 relates to a biologically degradable multi-component polymer fibre.

Improving the performance of packaging biodegradable container material continues to be a formidable undertaking, although several improvements have been made in both their materials and structures. However, increasing lifetime, mechanical strength, and eliminating leakage, without compromising thickness of the container material and particularly weight have not been met the desired needs of the consumer.

Accordingly, there exists a need for a biodegradable packaging container material to overcome the aforementioned drawbacks.

OBJECTS OF INVENTION

One or more of the problems of the conventional prior arts may be overcome by various embodiments of the present invention.

The primary object of the present invention is to provide a package container or bag material which is biodegradable and can replace the usage of plastic to store and transport chemicals like fertilizer, for an instance, urea.

Another object of the present invention wherein said package container or bag material is of environmentally friendly.

Another object of the present invention is to provide a method of preparing said package container or bag material comprising a plurality of layers of natural fibres and biopolymers. Another object of the present invention is to increase the usage of said natural fibers or fibres, either a fiber or fibre made of banana fiber, kenaf fiber, jute fiber, sisal fiber, Jute fiber, Cotton lint fiber, Hemp fiber, Coir fiber, Ramie fiber, Abaca fiber and similar natural fibers separately and/or in a combination of two or more of similar fibers in different weaving patterns with different compositions.

Another object of the present invention wherein said biopolymer layer made using either polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), Polycaprolactone (PCL), polybutylene succinate (PBS), poly hydroxybutyrate (PHB) and polyhydroxyalkanoates (PHA) and similar biopolymer materials separately or in a combination of two or more of similar biopolymers in various compositions.

Another object of the present invention wherein said polylactic acid (PLA), layer made by extracting cellulose from a plurality of sources, for instance newspaper and corn.

Another object of the present invention wherein said biopolymer blend allows the production of a hydrophobic layer or referred as a film.

Another object of the present invention wherein said hydrophobic layer prevents moisture from external influences.

Another object of the present invention is to improve a plurality of properties, including elasticity by adding either a synthetic or bio-based plasticizer, for an instance vegetable oil or cardinal oil or other similar plant-based oil.

Another object of the present invention is to use a plurality of compatibilizers, for an instance maleic anhydride to improve the stability and mechanical properties of multicomponent biopolymer blends. Another object of the present invention is to improve the mechanical strength of the natural fiber using various weaving patterns.

Another object of the present invention wherein said package container tested for its improved properties considering insoluble ash test, thermographic analysis test(TGA), tensile strength test, abrasion resistance test, water penetration and absorption test, differential scanning calorimeter(DSC) and similar tests described in IS9755, IS7406 testing procedures.

Another object of the present invention wherein said package container found to be recyclable as it comprises of sustainable materials.

Another object of the present invention is to reapply the biopolymer layer after wearing and tearing due to prolong usage.

SUMMARY OF INVENTION

Thus according to the basic aspect of the present invention, there is provided a biodegradable container, comprising of: at least two layers, namely a base layer and a superhydrophobic layer, wherein the superhydrophobic layer formed an inner surface of the biodegradable container, wherein the superhydrophobic layer made of biopolymer materials, wherein the base layer formed an outer surface of the biodegradable container, wherein the base layer made of blend of natural fibers.

It is another aspect of the present invention, wherein the superhydrophobic layer designed to provide a moisture barrier and impart superhydrophobic characteristics to the packaging container which forms the inner layer of the container which comes in contact with the packaged items, including fertilizers, and pesticides.

Another aspect of the present invention, wherein the superhydrophobic layer composed of largely biodegradable materials in addition to the biopolymers which made the container materials as sustainable, recyclable, and eco-friendly. The combination of biodegradable materials and biopolymers creates a hydrophobic barrier that repels water and prevents the ingress of moisture into the container. Said barrier is essential in preventing the spoilage of chemicals, for instance, caking of fertilizers, which can reduce the quality and effectiveness of the stored materials.

It is another aspect of the present invention, wherein the base layer composed of a blend of natural fibers that are weaved in a unique hessian pattern to create a strong and resilient material. The natural fibers used in the base layer include but are not limited to banana fiber, kenaf fiber, jute fiber, sisal fiber, cotton lint fiber, hemp fiber, coir fiber, ramie fiber, abaca fiber, and other similar natural fibers.

It is another aspect of the present invention, wherein the base layer of the packaging container designed to enhance the mechanical strength of the natural fibers by employing different weaving patterns. The weaving pattern can be customized based on the specific application requirements and the types of fibers being used to improve the mechanical strength and durability. The base layer is designed to withstand the rigors of storage and transportation while being environmentally friendly.

It is another aspect of the present invention, wherein the packaging container material and method of making sustainable packaging material, said material and method involve steps of: extracting of fibres; treating fibers with hot alkali; blending of various fibres; weaving in a special pattern to make a base layer [1]; pre-drying, blending of biopolymers, plasticizers, and compatibilizers; pelletization;

Film extrusion to make a superhydrophobic layer [2] ; and performing hot compression to bind the base layer and superhydrophobic layer, firmly. BRIEF DESCRIPTION OF DRAWING:

Figure 1 : illustrates a packaging container material according to the present invention.

Figure 2: illustrates a method of preparing the packaging container material according to the present invention.

Figure 3 : shows an insoluble ash test result report performed for the packaging container material according to the present invention.

Figure 4: shows a thermographic analysis test result report performed for the packaging container material according to the present invention.

Figure 5: shows a tensile strength test result report performed for the packaging container material according to the present invention.

Figure 6: shows an abrasion resistance test result report performed for the packaging container material according to the present invention.

Figure 7 : shows a water penetration and absorption test result report performed for the packaging container material according to the present invention.

Figure 8: shows a differential scanning calorimeter test result report performed for the packaging container material according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWING

The present invention as herein described relates to a cost-effective, biodegradable, sustainable packaging container material thereby protecting packaged materials, including fertilizers and pesticides from external adversaries like moisture for longer period. The container material according to the present invention is biodegradable, recyclable, sustainable, durable, long- lasting, and can be easily maintained and repaired.

Referring to Figure 1, the container material [100], comprises of two layers namely a base layer [1] and a superhydrophobic layer [2].

Components/ ingredients of the base layer:

The natural fibers include but are not limited to banana fiber, kenaf fiber, jute fiber, sisal fiber, cotton lint fiber, hemp fiber, coir fiber, ramie fiber, abaca fiber, and other similar natural fibers. In one embodiment, the base layer is made of a blend of jute and kenaf fibers.The blend was composed of at least 70% of jute fibre and at least 30% of kenaf fibre. The jute fibers provide high strength and durability, while kenaf fibers offer excellent hydrophobic properties. The combination of these two fibers results in a strong and durable material that can effectively resist moisture and protect the packaged chemicals from damage.

In another embodiment, the base layer is made of banana fiber and hemp fiber blended together in a proportion of at least 60% and 40%, respectively.The banana fibers provide excellent tensile strength and durability, while hemp fibers offer superior moisture resistance. The combination of these two fibers results in a material that is strong, durable, and resistant to moisture.

In yet another embodiment, the base layer is purely made of a blend of sisal fiber and coirjute fibers. Sisal fibers It provides high tensile strength and are resistant to abrasion, while coir fibers offering excellent water resistanceand durability. The abundance of this material makes it easy to source with its mechanical property and economical option, to make the base layer.

Source of the components/ingredients used in the present invention were procured from the following places:

Plant fibers (banana fiber, kenaf fiber, jute fiber, sisal fiber, cotton lint fiber, hemp fiber, coir fiber, ramie fiber, abaca fiber): Custom made from Anakaputhur Jute Weavers, Anakaputhur, Tambaram, Tamil Nadu.

Components/ ingredients of the superhydrophobic layer:

Poly-lactic Acid: 43%

Polybutylene Adipate Terephthalate: 43%

Biopolymers, such as PCL, PHA, and other similar materials: 10%

Plasticizers and compatibilizers, such as Malic anhydride: 4%

Source of the components/ingredients used in the present invention were procured from the following places:

Biopolymers procured from local vendors. Plasticizers and compatibilizers procured from local vendors.

Combination of Biopolymer materials: The combination of these materials creates a bio-polymer blend that is both sustainable and eco-friendly.

Plasticizers and compatibilizers: Improve the compatibility between the bio-polymer blend and the natural fibres in the base layer.

Preparation method:

Referring to Figure 2, in an aspect, the preparation procedures involved in making the container material illustrated.

Base layer [1]:

Extraction of Fibers: The first step involves extracting natural fibers, such as banana fibre, kenaf fibre, jute fiber, sisal fibre, cotton lint fiber, hemp fiber, coir fiber, ramie fiber, abaca fiber, or similar fibers, from their respective sources by retting and decortication.

Hot Alkali Treatment of Fibers: The extracted fibers are then subjected to an alkali treatment process to remove impurities and enhance fiber properties. The alkali treatment breaks hydrogen bonds between the hydroxyl groups (-OH) of the cellulose, hemicellulose and lignin and leads to defibrillation, the breakdown of the fiber bundle into smaller fibres. This treatment process significantly increases the resistance of the fibers to water and facilitates a stronger bond between the two layers. This treatment involves immersing the fibers in a hot alkaline solution, such as sodium hydroxide (NaOH), potassium hydroxide (KOH), or a similar alkali, followed by washing and drying.

Blending of Various Fibers: The treated fibers are blended in specific proportions to create a fiber blend that meets the desired characteristics for the base layer. The fiber blend may vary depending on the application requirements, and it can involve a combination of different natural fibers chosen for their specific properties. Weaving in a Special Pattern: The blended fibers are then subjected to a weaving process, where they are interlaced together in a special pattern. The weaving pattern is carefully selected to enhance the mechanical strength and durability of the base layer.

Superhydrophobic layer [2] :

Pre-drying: PLA and PBAT, the two main biopolymers, undergo a pre-drying process to remove any moisture present in them. The PLA and PBAT are placed in an oven and dried separately. PLA and PBAT are dried at 80°C for 6 hours, while PCL, another biopolymer used in the superhydrophobic layer, is pre-dried at a lower temperature compared to PLA and PBAT. It is dried at 45°C for 2 hours. This pre-drying step ensures that the biopolymers are free from moisture, which can affect the quality of the final product.

Blending of Biopolymers: The pre-dried PLA, PBAT, and PCL are then mixed in specific proportions. The biopolymers are combined in the following proportions: 43% PLA, 43% PBAT, 10% PCL, and 4% compatibilizers such as Malic anhydride. The compatibilizers enhance the compatibility between the different biopolymers, ensuring a homogeneous blend. The blending process is carried out using a twin screw extruder operating at a temperature of 160°C and a speed of 200 rpm. The extruder facilitates the thorough mixing and melting of the biopolymers, resulting in a homogeneous blend.

Pelletization: The blend of biopolymers is extruded through the twin screw extruder, which forms pellets of the desired size and shape. These pellets serve as the raw material for the subsequent film formation process.

Film Extrusion: The pellets obtained from the blending process are used to produce films, which will form the superhydrophobic layer. There are two options for film formation: blow film extrusion or T-die extrusion. In both methods, the pellets are heated to a temperature of 180°C and passed through the respective extrusion equipment. The extruder melts the pellets, and the molten material is then shaped into a continuous film. The film thickness can be adjusted as per the desired specifications. Heat Compression: Once the film is formed, it is heat compressed onto the base layer of the packaging container. A compression machine is used for this purpose. The film is placed on top of the base layer, and both are subjected to heat and pressure. The compression machine operates at a temperature of 150°C for a duration of 1 minute. The heat and pressure applied during this process ensure that the superhydrophobic layer adheres firmly to the base layer, forming a cohesive packaging material.

TEST RESULTS:

One of the embodiments utilizes packaging material comprised of pure jute fabric, coated with a biopolymer blend comprising 43% PLA, 43% PBAT, 10% PCL, 3% malic anhydride and 1% Cardinal Oil. This specific packaging material variant was tried and tested at the Council of Scientific and Industrial Research-Central Leather Research Institute (CSIR-CLRI) in Chennai, Tamil Nadu, India.

Referring to Figure 3, in an aspect, a test report for the analysis of water- insoluble ash, shown. The water-insoluble ash test provides crucial information about the inorganic matter present in the sample and serves as an indicator of the material's organic component purity.A low value of 0.9% insoluble ash indicates the percentage of material mass remaining after high temperature burning that cannot dissolve in water, revealing the presence of inorganic materials. The samples analyzed showed only minimal amounts of insoluble ash, implying that they are predominantly composed of organic materials with only trace amounts of plant-derived minerals present in the fibers. The insoluble test result indicates a high level of organic content, making it suitable as a sustainable bio alternative for fertilizer and pesticide packaging applications.

Referring to Figure 4, in an aspect, a thermographic analysis test report for the container material described in the present invention, shown. The thermographic analysis curve provides information about the thermal stability and degradation of the material. Based on the thermographic analysis curve of the container material, it can be inferred that the sample has two distinct thermal degradation transitions. The first transition occurs at 260°C, which is attributed to the thermal degradation of fiber, while the second transition occurs at 380°C, which is attributed to the thermal degradation of the polymer. Said thermographic analysis findings suggest that the material is thermally stable and can withstand high temperatures without any degradation until at least 260°C.

Referring to Figure 5, in an aspect, a test report of tensile strength conducted for the container material, shown. The tensile strength test, also known as the breaking load test, is a method employed to assess the strength of a material. This is achieved by subjecting the material to a gradually increasing tensile force at a point until it ultimately fractures or breaks. Based on the given result report, the average maximum point load at which the sample breaks are 51.36 kgf.

Referring to Figure 6, in an aspect, an abrasion resistance test result for the container material, shown. The abrasion resistance test is the method used to evaluate the ability of a material to resist wear or deterioration due to rubbing, friction, or other forms of mechanical action. Both the test samples have demonstrated good abrasion resistance. Having minimal damage during the Martindale abrasion test demonstrates that the material can withstand wear and tear and will maintain its integrity over time. It shows that both samples A and B incur no damage under 1600-3200 revolutions and exhibit a very slight abrasion loss at 12800 and 25600 revolutions when tested from the outer side. The fact that no holes were formed in the dry or wet samples of A and B during the Martindale abrasion resistance test is a positive indication that the sample can withstand repeated rubbing or friction without breaking down.

Referring to Figure 7, in an aspect, a test result of water impact analysis for the container material, shown. The water impact test is used to determine the ability of a material or to resist penetration or absorption of water. According to the test results, there was no water penetration observed even after 60 minutes, indicating that the material was effective in preventing water from passing through. However, the fiber layer did absorb water, as evidenced by a 23% increase in weight after 60 minutes— However, the aforementioned rise is of comparably minimal magnitude. Moreover, the average water transmission rate measures a mere 0.0365g, thereby guaranteeing the material's capability to shield the enclosed contents from water-induced impacts. The experimental assessment reveals an absence of water infiltration or absorption by the container material. Referring to Figure 8, in an aspect, a test result of differential scanning calorimeter (DSC) for the container material, shown. The DSC test measures the heat flow into or out of the material as a function of temperature, and the results help to determine the thermal stability of the material. From the results, it can be obtained that the Glass Transition Temperature (Tg) of the sample arrives at 40°C for both samples. Both the samples form endothermic peaks with almost the same melting temperature (Tm) onset at 115°C and peak at 122°C. The formed endothermic curve shows no crystallization with good thermal stability and melting at 122°C and induces 7J/g of heat flow out of the material. It is amorphous with a low degree of crystallinity thus improving barrier, mechanical and thermal properties.

Technical advancement:

The disclosed biodegradable superhydrophobic packaging container presents a notable technical advancement over existing solutions by addressing the shortcomings of both conventional plastic bags and biodegradable products. The unique features and advancements of this invention are as follows:

Biodegradable Superhydrophobic Layer: The inclusion of a superhydrophobic layer imparts superior moisture resistance to the packaging container. The layer is composed of a specific blend of biopolymers, including PLA, PBAT, PCL, and compatibilizers. This composition creates a hydrophobic barrier, preventing the ingress of moisture and thereby reducing the risk of caking and degradation of the stored fertilizers.

Mechanical Reinforcement: The base layer of the packaging container is reinforced with a blend of natural fibers, such as jute, kenaf, sisal, and other similar fibers. The unique weaving patterns employed enhance the mechanical strength and durability of the container, ensuring its suitability for robust storage and transportation of chemicals.

Biodegradability and Environmental Compatibility: The disclosed packaging container is entirely biodegradable. The utilization of natural fibers and biopolymers, which are derived from natural sources, promotes a reduced environmental impact. The container's ability to break down over time aligns with sustainable practices and facilitates responsible disposal. In comparison to conventional plastic bags and biodegradable products, the disclosed packaging container exhibits significant advantages. It surpasses conventional plastic bags by offering biodegradability, reduced environmental impact, and moisture resistance. Furthermore, it outperforms existing biodegradable products by providing mechanical strength and moisture barrier properties.

Advantages of the present invention:

Environmentally Friendly: The present invention offers a significant advantage over conventional plastic packaging materials by providing an environmentally friendly alternative. By utilizing biodegradable natural fibers and biopolymers, the invention reduces the reliance on non-biodegradable plastics and promotes sustainable practices.

Biodegradability: The packaging container/material of the present invention is designed to be biodegradable, meaning it can naturally break down over time without causing harm to the environment. This characteristic reduces the accumulation of non-biodegradable waste and contributes to the preservation of ecosystems.

Enhanced Protection: The multi-layer design of the packaging container/material provides improved protection for stored chemicals, such as fertilizers. The superhydrophobic layer acts as a moisture barrier, preventing the ingress of water and maintaining the quality and effectiveness of the stored materials. Additionally, the base layer, woven from natural fibers, offers mechanical strength and durability, ensuring the safe transportation and storage of the packaged chemicals.

Sustainable Materials: The present invention promotes the use of sustainable materials, such as natural fibers (e.g., jute, kenaf, sisal) and biopolymers (e.g., PLA, PBAT, PCL). By utilizing these materials, the invention reduces the reliance on non-renewable resources, supports agricultural practices, and contributes to a circular economy. Customizable Properties: The composition and weaving patterns of the base layer can be customized based on specific application requirements. This flexibility allows for the optimization of properties such as strength, moisture resistance, and durability, ensuring that the packaging container/material meets the desired specifications for storing and transporting chemicals.

Recyclability and Circular Economy: The materials used in the present invention, including the biodegradable natural fibers and biopolymers, can be easily recycled and repurposed after use. This characteristic promotes a circular economy by reducing waste and minimizing the environmental impact of packaging materials.

Versatility and Application Potential: The invention's use of various natural fibers and biopolymers allows for versatility in applications beyond fertilizers. The packaging container/material can be adapted for storing and transporting other chemicals, promoting the adoption of sustainable packaging solutions across different industries.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.