Plastic packaging waste currently forms a significant part of municipal solid waste and as such is causing increasing environmental concerns. Such packaging is largely non‐biodegradable and is particularly difficult to recycle or to reuse due to its complex composition. Apart from limited recycling of some easily identifiable packaging wastes, such as bottles, most packaging waste ends up in landfill sites. In recent years, in an attempt to address this problem in the case of plastic packaging, the development of packaging materials from renewable plant resources has received increasing attention and a wide range of bioplastic materials based on starch are now available. Environmentally these bioplastic materials also reduce reliance on oil resources and have the advantage that they are biodegradable and can be composted upon disposal to reduce the environmental impact.
Many food packaging containers are produced by thermoforming processes in which thin sheets are inflated under pressure into moulds to produce the required thin wall structures. Hitherto these thin sheets have almost exclusively been made of oil‐based polymers and it is for these that computational models of thermoforming processes have been developed. Recently, in the context of bioplastics, commercial thermoplastic starch sheet materials have been developed. The behaviour of such materials is influenced both by temperature and, because of the inherent hydrophilic characteristics of the materials, by moisture content. Both of these aspects affect the behaviour of bioplastic sheets during the thermoforming process.
This paper describes experimental work and work on the computational modelling of thermoforming processes for thermoplastic starch sheets in an attempt to address the combined effects of temperature and moisture content. After a discussion of the background of packaging and biomaterials, a mathematical model for the deformation of a membrane into a mould is presented, together with its finite element discretisation. This model depends on material parameters of the thermoplastic and details of tests undertaken to determine these and the results produced are given. Finally the computational model is applied for a thin sheet of commercially available thermoplastic starch material which is thermoformed into a specific mould. Numerical results of thickness and shape for this problem are given.
