This invention provides a finely ground biomass material used to create biomass-containing plastics having a smooth surface, while also preventing creation of unwanted color including those created by the Maillard reaction which results from a combination of sugars, protein, heat and acid or base chemicals. The present invention also provides for methods to prevent agglomeration of small particles into larger particles which can produce irregular surfaces on biomass-based plastics, including thin film plastics, especially thin film plastics less than 4 mil and other thin film plastics that can become too large to use in thin-film plastic production. For the purpose of this invention, plastic resins can be any gas or liquid hydrocarbon or fermentation-based resins.

Disclosed, among other things, are ways to manufacture layered structures. In one embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. These processes may be used to generate products with layered structures.

Disclosed is a biodegradable sheet comprising at least one layer which is a direct contact layer, intended to successfully contact materials, such as liquids, while maintaining the mechanical properties of the sheet and to extend the biodegradable sheet shelf life. The direct contact layer may comprise a hydrophobic polymer selected from poly(epsilon-caprolactone) (PCL) polyhydroxybutyrate (PHB), Polydioxanone (PDO) polyglycolic acid (PGA), polybutylene succinate (PBS), polybutylene succinate adipate (PBSA), poly lactic acid (PLA), polybutylene adipate terphtalate (PBAT), polyhydroxyalkanoates (PHA), such as polyhydroxybutyrates (PHB), polyhydroxyvalerates (PHV), and polyhydroxybutyrate-hydroxyvalerate copolymers (PHBV) or any mixture thereof. The biodegradable sheet may further comprise surface treated nanoclay particles, PVOH grafted with a crosslinker and PBS or PBSA The first hydrophobic polymer is present in said at least one layer in an amount of about 30% w/w.

An algae-based thermoplastic composition is provided that includes a protein-rich algae biomass selected from either microalgae, macroalgae or combinations thereof. The protein content is greater than or equal to 15% by weight of the algae biomass and the algae biomass is dried to a moisture content of less than or equal to 15% by weight and having a particle d99 of up to 200 microns. The dried algae biomass is at least 5% by weight of the thermoplastic composition. The composition includes a biodegradable resin configured to exhibit rheological properties suitable for blending with algae including a melting temperature less than 250 C. and a melt flow rate in excess of 0.01 g/10 min.

Disclosed is a biodegradable sheet comprising at least one layer which is a direct contact layer, intended to successfully contact materials, such as liquids, while maintaining the mechanical properties of the sheet and to extend the biodegradable sheet shelf life. The direct contact layer may comprise a hydrophobic polymer selected from poly(epsilon-caprolactone) (PCL) polyhydroxybutyrate (PHB), Polydioxanone (PDO) polyglycolic acid (PGA), polybutylene succinate (PBS), polybutylene succinate adipate (PBSA), poly lactic acid (PLA), polybutylene adipate terphtalate (PBAT), polyhydroxyalkanoates (PHA), such as polyhydroxybutyrates (PHB), polyhydroxyvalerates (PHV), and polyhydroxybutyrate-hydroxyvalerate copolymers (PHBV) or any mixture thereof. The biodegradable sheet may further comprise surface treated nanoclay particles, PVOH grafted with a crosslinker and PBS or PBSA The biodegradable sheet may further include at least one metalized, biodegradable, laminate layer.

The present invention provides expanded polylactic acid resin beads, in which each bead is composed of a core layer that is in an expanded state and contains a crystalline polylactic acid resin, and a coating layer that coats the core layer and contains a mixed resin of an amorphous polylactic acid resin and a crystalline polyolefin resin, wherein the content of the crystalline polyolefin resin in the coating layer is 3% by weight or more and less than 50% by weight. The expanded polylactic acid resin beads can stably produce a molded article of expanded polylactic acid resin beads excellent in fusibility of the expanded polylactic acid resin beads therein and also excellent in solvent resistance.

Disclosed herein is a porous material comprising a biopolymer functionalized with a carbon dioxide capturing moiety; where the biopolymer is in the form of a foam or an aerogel having a bulk density of 500 grams per cubic meter to 2500 grams per cubic meter. Disclosed herein too is a method comprising functionalizing a biopolymer with a carbon dioxide capturing moiety; dissolving the biopolymer in an aqueous solution to form a first solution; reducing the temperature of the first solution to below the freezing point of the aqueous solution; displacing the aqueous solution with a first solvent that has a lower surface tension than a surface tension of the aqueous solution; and drying the first solvent to produce a porous biopolymer having a bulk density of 500 grams per cubic meter to 2500 grams per cubic meter.

Disclosed, among other things, are ways to manufacture reduced density thermoplastics using rapid solid-state foaming and machines useful for the saturation of plastic. In one embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity. In another embodiment, a foaming process may produce layered structures in reduced density plastics with or without integral skins. In another embodiment, a foaming process may produce deep draw structures in reduced density plastics with or without integral skins. In yet another embodiment, a foaming process may utilize additives, blends, or fillers, for example. In yet another embodiment, a foaming process may involve saturating a semi-crystalline polymer such as Polylactic Acid (PLA) with high levels of gas, and then heating, which may produce a reduced density plastic having high levels of crystallinity.

Provided is a method with which a biodegradable polyester film containing polyhydroxyalkanoate can be stably produced by film blowing under practical processing conditions. A method for producing a biodegradable polyester film containing a biodegradable aliphatic polyester (A) and a fatty acid amide (B) by film blowing, the biodegradable aliphatic polyester (A) containing polyhydroxyalkanoate, the method including: a step (I) of dry-blending the biodegradable aliphatic polyester (A) with a masterbatch containing the fatty acid amide (B) and a base material resin; and a step (II) of subjecting the mixture obtained in the step (I) to film blowing.

The invention pertains to a biodegradable coating composition, comprising a crosslinked starch and a filler, and optionally a polyol plasticizer, as well as to outside structures such as greenhouses, comprising a coating layer obtained by drying the said coating composition. The invention furthermore pertains to removal of the coating layer using a targeted cleaning composition.