{"id":3139,"date":"2026-09-08T12:50:36","date_gmt":"2026-09-08T12:50:36","guid":{"rendered":"https:\/\/plastrans.kinsta.cloud\/?p=3139"},"modified":"2026-09-08T12:51:36","modified_gmt":"2026-09-08T12:51:36","slug":"plastics-and-innovation","status":"publish","type":"post","link":"https:\/\/www.plastrans.com\/en\/plastics-and-innovation\/","title":{"rendered":"Plastics and Innovation"},"content":{"rendered":"<!-- Bild -->\n    \n\n    <div data-aos=\"fade-up\" data-aos-duration=\"1000\"  class=\"ce ce-text\n             \" id=\"\">\n        \n        <div class=\"container-fluid\">                <div class=\"row\">\r\n        <div class=\"col-12 col-md-12 col-xl-12 mx-auto text-left\">\r\n            <h2 class=\"h2\">From Compound to Extruder: How Dry Blending Is Rewriting the Economics of Biobased Film <\/h2>\r\n        <\/div>\r\n    <\/div>\r\n\r\n                        <div class=\"row\">\n                <div class=\"ce-text__text col-12 col-md-12 col-xl-12 mx-auto text-left\">\n                    <p>Our recent LinkedIn post introducing dry blending technology generated considerable interest across our network \u2014 a clear sign that this development is relevant to a broad range of film producers.\u00a0We would like to build on that discussion with a development from our long-standing technology partner\u00a0<strong>BioLogiQ<\/strong>, achieved together with blown film equipment specialist\u00a0<strong>Reifenh\u00e4user<\/strong>: the successful direct blending of\u00a0BioLogiQ&#8217;s\u00a0thermoplastic starch biopolymer\u00a0<strong>NuPlastiQ\u2122<\/strong>\u00a0at the extruder,\u00a0eliminating\u00a0the separate compounding step entirely.<\/p>\n<p>On the surface, this reads as a process detail. In practice, it has meaningful implications for the cost structure and flexibility of biobased film production.<\/p>\n<p><strong>The problem with compounds<\/strong><\/p>\n<p>Most starch\u00a0containing\u00a0film applications today rely on pre-compounded material\u00a0\u2013 typically,\u00a0NuPlastiQ\u00a0and the carrier resins are compounded in a fixed ratio in a compounding step. Depending on the application\u00a0the such\u00a0produced compound is either used as a masterbatch to be diluted or as is.<\/p>\n<p>That step carries a measurable cost:\u00a0on large scale\u00a0compounding alone typically adds between 0.30 and 0.45 EUR per kilogram on top of raw material costs, before accounting for\u00a0the overhead,\u00a0logistics of shipping a compound, the inventory required to carry it, and the loss of purchasing leverage that comes from buying a finished blend rather than sourcing the raw polymers directly.<\/p>\n<p>It also introduces a degree of inflexibility. Once a compound is fixed, the film producer is tied to whichever\u00a0carrier resin\u00a0the compounder used;\u00a0fine-tuning film properties for a specific\u00a0application, or\u00a0switching to the\u00a0material\u00a0grade already run on other lines, requires going back to the compounder.<\/p>\n<p><strong>Feeding the ingredients straight into the line<\/strong><\/p>\n<p>BioLogiQ\u00a0set out to test whether that compounding step could simply be eliminated \u2014 feeding\u00a0NuPlastiQ, an LLDPE copolymer, and a compatibilizer directly into the extruder as separate components, rather than as a pre-made\u00a0compound.<\/p>\n<p>For the trial, they partnered with\u00a0Reifenh\u00e4user, whose EVO Fusion 5-layer blown film line is built around a twin-screw extruder for the core layer,\u00a0originally designed for processing recycled\u00a0PE,\u00a0with\u00a0the vacuum venting and melt-pump technology needed to handle multi-component feeds directly at the line.<\/p>\n<p>The results, run at production-relevant rates of up to 470 kg\/hr, were unambiguous. Films made by\u00a0direct-feeding\u00a0the individual components matched the benchmark compound on every measure that\u00a0matters:\u00a0transparency, mechanical tear resistance, and impact strength. Even a reduced compatibilizer dose,\u00a0tested specifically to see how far the recipe could be\u00a0pushed,\u00a0still\u00a0produced an acceptable film, just with\u00a0somewhat more\u00a0haze. Across the\u00a0very first\u00a0trial series, biobased content in the finished film reached up to 26.4%, with the door open to 30% and beyond.<\/p>\n<p>In short: what used to require a separate compounding facility can now happen in a single pass, on equipment\u00a0that many sustainable material converters will be interested in anyhow,\u00a0or are already evaluating for other reasons.<\/p>\n<p><strong>Why this matters more than it looks<\/strong><\/p>\n<p>The cost\u00a0savings\u00a0from\u00a0eliminating\u00a0compounding is the headline. But\u00a0we see\u00a0at least three further implications that deserve equal attention.<\/p>\n<ol>\n<li><strong> An intermediate-polarity layer that bridges incompatible materials<\/strong><\/li>\n<\/ol>\n<p>Within the recipe\u00a0NuPlastiQ\u00a0occupies an intermediate position on the polarity spectrum \u2014 more polar than standard polyolefins, less polar than materials such as EVOH or polyamide. Blended directly at the extruder, this intermediate-polarity dry blend does more than contribute biobased content: it\u00a0possibly\u00a0can\u00a0also function as a\u00a0compatibilizing\u00a0layer, supporting adhesion between polar and non-polar layers within the same multilayer structure.\u00a0This opens doors for further investigations with respect to a tie-layer functionality.<\/p>\n<ol start=\"2\">\n<li><strong> A cost lever inside biobased-PE structures<\/strong><\/li>\n<\/ol>\n<p>The biobased-content conversation defaults, in many cases, to biobased PE \u2014 which carries a significant cost premium over conventional polyolefins.\u00a0NuPlastiQ\u00a0is priced well below that premium. Used as a dry-blended\u00a0component\u00a0within a biobased-PE film structure, it allows producers to reach the same biobased-content target at a meaningfully lower material cost, while\u00a0retaining\u00a0the &#8220;bio-based&#8221; positioning that some customers specifically\u00a0require.<\/p>\n<ol start=\"3\">\n<li><strong> A template for what comes next: compostable polyesters<\/strong><\/li>\n<\/ol>\n<p>The direct-feed, no-compounding approach that\u00a0BioLogiQ\u00a0and\u00a0Reifenh\u00e4user\u00a0have\u00a0validated\u00a0for\u00a0NuPlastiQ\u00a0and LLDPE also\u00a0establishes\u00a0the technical basis for dry blending\u00a0NuPlastiQ\u00a0with compostable polyesters, again without a separate compounding step. Should this development\u00a0proceed\u00a0as the current trial suggests, it would make\u00a0NuPlastiQ-based starch compounds\u00a0substantially more\u00a0cost-competitive and accessible to a broader base of film producers, extending well beyond the LLDPE-based applications\u00a0demonstrated\u00a0here.<\/p>\n<p><strong>Where this leaves film producers today<\/strong><\/p>\n<p>Notably, this does not require\u00a0an entirely\u00a0new\u00a0type of\u00a0equipment. The line configuration used in\u00a0BioLogiQ&#8217;s\u00a0trial was not\u00a0modified,\u00a0only the process parameters were adapted. For converters\u00a0operating\u00a0or evaluating equipment with the\u00a0appropriate feeding\u00a0and venting capability, the barrier to entry for direct-blended biobased film has been\u00a0substantially lowered.<\/p>\n<p>BioLogiQ\u00a0regards this milestone as a starting point rather than an\u00a0endpoint and\u00a0continues to pursue further optimization together with\u00a0Reifenh\u00e4user.<\/p>\n<p>As a long-standing distributor of\u00a0NuPlastiQ\u00a0across the region,\u00a0Plastrans\u00a0regularly discusses cost-competitive routes to biobased content with packaging engineers and procurement teams. This development is precisely the kind of advance we consider worth bringing to our partners&#8217; attention early.<\/p>\n<p><strong>To discuss whether direct dry blending is a fit for your line, or how\u00a0NuPlastiQ\u00a0could be applied within your current film structure, please contact our team.<\/strong>\u00a0We are glad to walk through the technical details and, where useful, connect you directly with\u00a0BioLogiQ&#8217;s\u00a0experts.<\/p>\n                <\/div>\n            <\/div>\n        <\/div>    <\/div>\n\n    ","protected":false},"excerpt":{"rendered":"<p>We would like to build on that discussion with a development from our long-standing technology partner BioLogiQ, achieved together with blown film equipment specialist Reifenh\u00e4user<\/p>\n","protected":false},"author":9,"featured_media":10837,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"mc4wp_mailchimp_campaign":[],"footnotes":""},"categories":[5],"tags":[],"class_list":["post-3139","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-plastics-and-innovation"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.2 - 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