Background
Biopolymers are gaining attention as renewable and compostable alternatives to fossil-derived plastics, but their sensitivity to moisture continues to limit widespread use. This challenge is particularly acute in packaging, biomedical, and consumer goods, where stability under humid conditions is essential. Current industry practice relies on drying biopolymer pellets for several hours at high temperatures before processing, a step that consumes large amounts of energy and adds significant cost. Reducing or eliminating this drying requirement would lower manufacturing costs, cut carbon emissions, and accelerate adoption of sustainable materials, directly supporting the UK’s transition to net zero.
Project Details and Results
This project investigated the effectiveness of a modified desiccant additive as an in-process solution to improve the stability and performance of biopolymers. More than 40 extruded tapes and several moulded sheets were produced and tested under both dry and high-moisture conditions. With advanced characterisation and data analysis at Royce Manchester, and complementary chemical, mechanical, and thermal testing at Loughborough, the team demonstrated that the additive significantly reduces porosity, enhances stability, and maintains strength even when materials are processed in humid environments. At lower loadings (around 0.5%), the approach proved particularly effective in balancing performance with processability.
Crucially, results indicate that the drying stage before extrusion could be reduced or even removed. For a typical production line processing 1,000 tonnes of material per year, this could save 100,000–250,000 kWh of energy, offering substantial gains in cost efficiency and carbon reduction.
The work demonstrates a credible route to lower-carbon, lower-cost biopolymer manufacturing, with immediate relevance to packaging, biomedical components, and consumer goods where demand for sustainable materials is accelerating.
Overall, the project provides compelling evidence that in-process desiccants can make renewable plastics more competitive and expand their market impact.
Collaborators
This project investigated the use of a modified desiccant additive to enhance the processing and stability of biopolymers. By reducing moisture sensitivity and potentially eliminating the need for energy-intensive drying, the innovation provides a practical route towards lower-carbon, lower-cost manufacturing of sustainable materials.
Supported by Royce ICP funding, the collaboration between Loughborough University and Virdis Chemicals Ltd accessed XCT facilities and expertise at Royce Manchester to validate the concept and de-risk future industrial uptake.
"This project provides the first clear evidence that an in-process desiccant additive can overcome the moisture sensitivity of biopolymers, offering a practical route to lower-carbon, lower-cost manufacturing and opening new opportunities for sustainable products."
Dr Yi Liu, Senior Lecturer in Polymers and Composites
Loughborough University
