Plastic pollution has become a global crisis. From overflowing landfills to microplastic pollution in the ocean and food chain, the environmental impact of traditional plastics urgently requires a sustainable alternative. This has propelled the manufacturing of biodegradable plastics to the forefront of environmental innovation, providing a crucial solution for reducing waste and promoting a circular economy.
As a leading compostable packaging bag manufacturer in China , ORIZON is committed to pioneering these sustainable solutions. This guide will take you through “Biodegradable Plastic How to Make,” from its fundamental principles and various material types to the advanced technologies used to produce high-quality, truly environmentally friendly packaging materials. Learn how we translate scientific advancements into tangible, planet-friendly products, redefining sustainable plastic alternatives.
What is Biodegradable Plastic
To truly understand the production process of biodegradable plastics, one must first understand their nature. Biodegradable plastics are materials that, under specific conditions, can naturally decompose into biomass, carbon dioxide, and water through the action of microorganisms. This is fundamentally different from traditional plastics, which can last for hundreds of years.
Difference Between Biodegradable and Compostable
Compostable plastics are all biodegradable; they are a branch of biodegradability. However, not all biodegradable plastics are compostable.
The production of compostable plastics specifically refers to materials that can completely decompose within a composting environment (industrial or domestic, depending on certification) within a specific timeframe, leaving no toxic residues. ORIZON has focused on certified compostable plastics for 16 years, ensuring our products seamlessly integrate into existing organic waste management processes.
To learn more about biodegradable versus compostable, watch this article：Compostable vs Biodegradable: 2025 Comprehensive Guide
The main types of biopolymers commonly used in bioplastics production include:
- Polylactic acid (PLA): A widely used plant-based plastic made from renewable resources such as corn starch or sugarcane. Its production process involves fermenting sugar into lactic acid, followed by polymerization. PLA is known for its transparency and rigidity.
- Polybutylene terephthalate (PBAT): PBAT is often used in blends and is a flexible, petroleum-based biodegradable plastic with excellent film-forming properties, making it ideal for manufacturing biodegradable plastic bags and films. Its synthesis process ensures complete degradation.
- Polyhydroxyalkanoates (PHA): Naturally occurring polyesters produced by various microorganisms through the fermentation of organic matter. PHA has a wide range of applications, combining the properties of biodegradable plastics with the rigidity and flexibility of traditional plastics.
- Starch-based plastics: Modified starch is often blended with other biopolymers to produce cost-effective and environmentally friendly plastics suitable for a variety of applications. Corn starch plastics are particularly common in this production process.
To learn more What Is PLA? Ultimate Guide to Biobased Fully Biodegradable Industrial Plastics
Biodegradable Plastic Manufacturing Process: From Raw Materials to Polymers
Understanding how to manufacture biodegradable plastic involves a fascinating journey from natural resources to functional polymers. The biodegradable plastic manufacturing process steps are carefully controlled to ensure the resulting material possesses both desirable performance characteristics and guaranteed degradability.
Where do Biodegradable Plastics come from?
The foundation of bioplastics production lies in its raw materials, with a particular emphasis on renewable resources:
- Bio-based sources: Many plant-based plastics are primarily derived from corn starch, sugarcane, cassava, and other agricultural products. These raw materials provide the sugars needed for fermentation, converting them into monomers (such as lactic acid), which are then polymerized.
- Microbial fermentation: In the production of PHA plastics, specific microorganisms are fed organic compounds, which naturally produce PHA and store it within their cells as an energy reserve.
- Petroleum-based biodegradable materials: While generally bio-based, some materials (such as PBAT) can also be derived from petroleum; however, their molecular structures are engineered to be completely biodegradable under specific conditions. The key is their degradation capability, not just their source.
Core Production Steps: Polymerization and Granulation
- Raw Material Acquisition and Pretreatment: Agricultural raw materials are processed to extract sugars or starches. For microbial fermentation, specific nutrient media need to be prepared.
- Monomer Production: Through processes such as fermentation, sugars are converted into basic structural units (monomers). For example, the monomer of PLA is lactic acid.
- Polymerization: This is the core of biodegradable plastic production. Monomers are linked by chemical bonds to form long chains, thereby generating polymers. The chemical reaction pathways at this stage differ between PLA plastic production and PBAT synthesis.
- Mixing and Modification: Biopolymer raw materials often require further processing. Additives can enhance the properties of biodegradable plastics, such as strength, flexibility, heat resistance, or processability. This step is crucial for materials customized for specific products, such as biodegradable plastic bags.
- Granulation: Refined bioplastics are made into small granules, which are the standard form for subsequent processing methods (such as extrusion or molding) and ultimately into finished products.
Key Technologies and Challenges in Bioplastics Development:
The development of biodegradable plastics is a complex field requiring continuous innovation.
- Performance Balancing: Achieving optimal performance (e.g., durability, elasticity, and barrier properties) while ensuring rapid and complete degradation of biodegradable plastics remains an ongoing technological challenge.
- Cost-Effectiveness: Scaling up bioplastics production to compete with conventional plastics requires continuously improving production efficiency and optimizing raw material sourcing. The production cost of biodegradable plastics is a significant factor.
- Controlled Degradation: Ensuring that the degradation mechanisms of bioplastics function effectively in their intended final disposal scenarios (e.g., industrial composting vs. home composting) is crucial.
How Much Does It Cost to Make Biodegradable Plastic
Besides the technological complexities, the economic feasibility of producing biodegradable plastics is a key challenge and a frequent concern for companies exploring sustainable solutions. The question, “What is the cost of producing biodegradable plastics?” directly impacts market acceptance and competitiveness against conventional plastics. This section will introduce the main factors influencing these costs, which are closely related to each step of the entire biodegradable plastics production process we have discussed.
Raw Material Costs:
- Basic: Unlike petroleum-based plastics, bioplastics production is highly dependent on renewable resources such as corn starch, sugarcane, or agricultural waste. The prices of these agricultural raw materials fluctuate significantly, influenced by harvest, global food markets, and seasonal factors.
- Conversion Complexity: Extracting monomers (such as lactic acid used to produce polylactic acid) from biomass and converting them into polymers is typically more complex and energy-intensive than a simple crude oil refining process. This initial conversion significantly increases the total production cost of polyhydroxyalkanoates (PHA) or the raw material cost of polylactic acid (PLA).
- Additives: To achieve the desired properties of biodegradable plastics (such as flexibility and heat resistance), specialized, bio-based additives are often added, further increasing the production cost of biodegradable plastics.
Production Process Costs:
- Specialized Technology: From biopolymer synthesis to extrusion molding, the production processes for biodegradable plastics may require more specialized equipment and more precise control than conventional plastic production lines. This results in higher capital investment and operating costs.
- Energy Consumption: Certain polymerization methods or biopolymer production technologies require specific chemical reactions and processing temperatures that lead to higher energy consumption, thus impacting overall production efficiency. R&D Amortization: The substantial R&D investment required to develop and refine sustainable plastic alternatives is amortized across various production units, thus driving up unit costs.
Certification and Compliance Costs:
Obtaining and maintaining compostability standard certifications such as EN 13432, ASTM D6400, or BPI requires rigorous testing and administrative fees. While these costs are crucial for market reputation and trust, they also directly impact the final price. This answers the frequently asked question about the true cost of truly environmentally friendly standards.
While these factors currently result in higher market prices for biodegradable plastics compared to conventional plastics, ongoing technological innovation and expanding economies of scale are continuously reducing these costs. However, the true value extends far beyond unit price; it also includes environmental benefits and the growing market demand for truly sustainable plastic alternatives.
Applications and Future of Biodegradable Plastic
The rapidly growing demand for sustainable plastic alternatives has driven the production of bioplastics across various sectors. Beyond our compostable packaging bags, the applications of biodegradable plastics are extensive:
- Packaging Industry: Food packaging, consumer product packaging, and environmentally friendly packaging materials are the main drivers.
- Agriculture: Biodegradable mulch films offer a solution for plastic waste generated in agriculture.
- Disposable Products: Tableware, cups, and plates made from biopolymers.
- Medical Industry: Biodegradable sutures and drug delivery systems.
The future of bioplastics manufacturing is bright, driven by increasing consumer awareness, clearer corporate sustainability goals, and increasingly stringent environmental regulations. The global transition to a circular economy further reinforces the crucial role of biodegradation as a responsible final disposal solution for plastic products. We will continue to focus on the research and development of biodegradable polymers to maintain our leading position in this exciting field.
How to Turn “Biodegradable” into “Compostable Bags”
At Orizon, our deep understanding of biodegradable plastic production processes translates directly into our compostable bag products. We not only supply bags, but also provide certified sustainable solutions based on rigorous science and sophisticated manufacturing processes.
Commitment to Sustainable Raw Materials:
We select high-performance biopolymers, primarily using advanced PLA/PBAT blends. These materials are carefully chosen for their strength, flexibility, and biodegradability, ensuring reliable performance during use and responsible degradation afterward. We are committed to ensuring a transparent and sustainable supply chain for all raw materials.
Advanced Manufacturing Processes and Technologies:
Our state-of-the-art facility utilizes cutting-edge extrusion technology to produce thin, durable biodegradable films. Our biodegradable plastic production process is strictly controlled:
- Precise Mixing: Specialized formulations ensure ideal mixing ratios of biopolymers and additives to meet specific product requirements.
- Optimized Extrusion: Our calibrated equipment efficiently processes bioplastics, producing high-strength, stable films suitable for various types of packaging bags.
- Strict Quality Control: Every batch undergoes comprehensive testing for tensile strength, tear strength, seal integrity, and film thickness to meet our stringent standards.
Compliant with International Compostable Standards:
Our compostable packaging bags are not merely “biodegradable”—they have passed stringent international compostable standard certifications. We hold the following certifications:
- EN 13432 (Europe): This standard specifies the requirements for packaging materials to be recycled through composting and biodegradation, including minimum biodegradability and ecotoxicity testing.
- ASTM D6400 (USA): Similar to EN 13432, this standard specifies the standards for plastics that can be composted in municipal and industrial facilities.
- BPI Certification (USA): The Biodegradable Products Institute (BPI) certification program is a widely recognized compostability verification in North America.
These certifications ensure that our products can completely and safely decompose in industrial composting facilities, leaving no harmful residues. This eliminates concerns about “green washing” and ensures that our customers are investing in truly environmentally friendly plastics.
Click here to view our certificates：https://orizonbags.com/download-compostable-bag-catalog/
Comprehensive Product Range:
Leveraging our expertise in bioplastics production, we offer a wide variety of biodegradable plastic bags and films:
- Compostable Shopping Bags: Durable, printable with brand logos, suitable for retail use.
- Compostable Garbage Bags: Sturdy, leak-proof, suitable for collecting organic waste.
- Pet Bags: Meeting the needs of the pet market, easy to carry, leak-proof and waterproof.
- Compostable Mailing Bags: Providing a sustainable solution for e-commerce.
- Compostable Clothing Bags: Meeting the brand image needs of businesses, lightweight and flexible.
- Custom Packaging Solutions: Tailor-made biodegradable films and bags to specific product requirements.
What Are the Problems with Biodegradable Plastics?
- Strict Degradation Conditions: Biodegradable plastics will naturally disappear in any natural environment, such as a home compost heap or the ocean. Most certified biodegradable and compostable plastics (such as PLA or PBAT mixtures) require specific industrial composting conditions. This means high temperatures (typically 55-60°C), controlled humidity, and the presence of a specific microbial community. Without these conditions, even if they degrade, the rate is extremely slow, and they may remain in landfills or the natural environment for years, just like conventional plastics. Home composting rarely results in complete degradation.
- Contamination of Recycling Processes: Impact on existing recycling infrastructure. Mixing biodegradable plastics with conventional plastics (such as PET or HDPE) in recycling bins contaminates the recycling process, rendering the entire batch of recyclable material unusable. This is because their chemical structures differ and cannot be processed together with conventional plastics. Systems specifically designed for the collection and processing of biodegradable plastics remain scarce globally.
- Higher Production Costs: The production cost of biodegradable plastics is generally higher than that of conventional petroleum-based plastics. This cost difference may hinder their widespread adoption, especially in price-sensitive markets. While economies of scale are gradually improving, this remains a challenge for many businesses.
- Limited performance in some applications: Depending on the specific type of biodegradable plastic, some may have limitations compared to conventional plastics in terms of heat resistance, barrier properties (e.g., moisture or oxygen protection), or mechanical strength. This means they cannot always directly replace all plastic applications.
- Microplastic formation risk: If biodegradable plastics cannot completely degrade in the intended environment (e.g., if industrial composting is not possible), they will still break down into smaller fragments, potentially causing microplastic pollution, despite their different chemical origins.
- Consumer confusion and labeling errors: Terms such as “biodegradable,” “compostable,” and “bio-based” are often used interchangeably or lack clear explanations, causing significant consumer confusion. This can lead to incorrect disposal methods, diminishing intended environmental benefits and hindering the development of effective waste management systems.
Are Biodegradable Plastics Good for the Environment?
Are biodegradable plastics good for the environment? The answer is nuanced and depends heavily on context, proper infrastructure, and consumer behavior.
Advantages:
- Reduced Dependence on Fossil Fuels: Many biodegradable plastics are bio-based, derived from renewable resources such as corn starch, sugarcane, or other biomass. This reduces our reliance on finite fossil fuels and lowers the carbon footprint during production compared to conventional plastics.
- Reduced Landfill Waste: Properly processed in certified industrial composting facilities, biodegradable plastics can avoid landfilling or incineration, helping to reduce landfill waste and greenhouse gas emissions associated with their decomposition.
- Advantages in Specific Applications: In certain applications where recycling is difficult (e.g., agricultural mulch that can be tilled into the soil) or where high biodegradability is required (e.g., medical sutures), biodegradable plastics offer significant environmental and functional advantages.
- Potential Reduction of Plastic Pollution in Sensitive Environments: While not a panacea for ocean pollution, some studies suggest that certain biodegradable polymers may decompose faster than conventional plastics in specific natural environments, potentially mitigating long-term plastic accumulation. However, this area requires continued research and refinement.
Factors Affecting Environmental Benefits:
- Infrastructure: Environmental benefits largely depend on the availability of appropriate waste management infrastructure (e.g., widely used industrial composting facilities) and effective sorting systems. Without these, their “biodegradable” nature is virtually meaningless in practice.
- Life Cycle Assessment (LCA): A life cycle assessment is necessary to truly understand environmental benefits. LCA analyzes the environmental impact of materials throughout their entire lifecycle, from raw material extraction, manufacturing, use to final disposal. Factors such as land use, water consumption, and energy consumption during processing all influence the overall environmental footprint and, if mismanaged, can sometimes negate the perceived “green” advantages.
- Reduce, Reuse, Recycle: With biodegradable plastics, the fundamental principles of reduction, reuse, and recycling remain among the most effective strategies for environmental protection. Biodegradable plastics should be viewed as a tool in the broader sustainability toolkit, not a substitute for these core practices, especially regarding single-use items.
Why Choose Us: More Than Products, A Sustainable Partnership
Choosing orizon means partnering with a leader in sustainable plastic alternatives. We are dedicated to providing not just high-quality products, but comprehensive solutions backed by unparalleled expertise.
- Unparalleled Expertise: A deep understanding of the manufacturing process for biodegradable plastics means we control every step of the product’s production, from raw material selection to the final degradation mechanism.
- Guaranteed Quality and Performance: Our rigorous quality control ensures our compostable bags are reliable and meet diverse application needs.
- Global Compliance and Service: We are capable of meeting international standards and supply chains, supporting global businesses in their transition to sustainable development.
Success Stories:
We help companies achieve their environmental goals. Walmart, a globally renowned supermarket chain, reduced its plastic waste by 70% within a year of adopting our certified compostable shopping bags.
FAQ
Will your compostable bags really degrade in home composting?
While our bags meet industrial composting standards, home composting conditions vary greatly. For optimal biodegradation, we recommend using a strictly temperature- and humidity-controlled industrial composting facility.
What is the shelf life of your compostable bags?
Our bags are designed for stability and ease of storage and use. When stored in a cool, dry environment, they typically last 12-18 months.
You can check out this article: How to Store Compostable Bags Correctly：Extending Shelf Life
How should I dispose of used compostable bags?
Please always dispose of them in the designated organic waste bins so they can be sent to an industrial composting facility for processing. This ensures they degrade completely.
You can check out this article: How to Dispose of Compostable Bags: Your Ultimate Guide
How to identify genuine compostable products in a market saturated with “green marketing”?
Always look for clear certification marks from reputable third-party organizations (such as BPI, Seedling, OK Compost). This is an absolute guarantee of genuine compostability.
Conclusion:
The development of biodegradable plastics fully demonstrates humanity’s remarkable wisdom in pursuing environmental responsibility. At ORIZON, we are proud to be at the forefront of this innovative field, transforming complex biopolymer production technologies into practical, efficient, and environmentally friendly plastics, contributing to a better planet.
We invite you to explore our range of certified compostable bags and learn how our commitment to quality, science, and sustainability can enhance your brand image and contribute to a healthier environment. Join us in creating a future where plastic waste is no longer a problem.
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