Alpha Packaging is known for getting involved early in new technologies and processes. Among the newest products we are bringing to market are bottles and jars made from NatureWorks PLA (Polymerized Lactic Acid), a plastic resin derived from corn byproducts.

NatureWorks, a wholly-owned subsidiary of Cargill, has made PLA into a viable plastic resin that requires about 20% to 30% less energy to produce and contributes only half the carbon dioxide than plastics made from petrochemicals. Through a special co-branding agreement, Alpha Packaging is now running the fully-compostable resin on our PET stretch blow-molding machines. Many styles of our PET molds are compatible with the resin, so please ask your Sales Representative if you are interested in testing a particular bottle style. You can also request a sample of PLA bottles by visiting our Product Catalog and clicking on the Sample Packs link on the left.

Because PLA is made from corn instead of petrochemicals, and requires significantly less energy to produce, its costs may not fluctuate as dramatically as petroleum-based resins. For companies currently packaging products in polyethylene terephthalate (PET) or polystyrene, NatureWorks PLA may offer an interesting alternative to current packaging. Some of the questions you may have about PLA include:

What products work best in NatureWorks PLA? PLA is ideal for oil-based products, as well as products with flavor and aroma attributes. PLA has also successfully housed many types of solvents, and Alpha can work with NatureWorks to provide existing test data or perform new tests. We recommend that all of our customers test their products in PLA containers prior to sending them to market.

What are the barrier characteristics of NatureWorks PLA and how do they impact my product's shelf life? Compared to PET, uncolored PLA bottles have approximately eight times the transmission rate for both water and oxygen. However, adding colorants to the resin can reduce the transmission rates. If your product is water-based, PLA might not be the best choice if you need extended shelf life (more than several months). For moisture-sensitive products, we recommend testing to determine compatibility.

Can foods and nutritional products be packaged in NatureWorks PLA? The PLA resin is FDA-approved and suitable for food contact. It is widely used for dairy, juice and water bottles, as well as trays for deli meats, salads and single-serve meals.

Are there products that should not be packaged in NatureWorks PLA? PLA is made from polylactic acid, so products composed of a strong base chemical may not be suited for PLA. Also, some water-based products may not be well-suited for PLA since the water can evaporate over time, altering the product's composition.

Can NatureWorks PLA bottles withstand freezing? What about heat? Filled PLA bottles can be frozen and thawed successfully, and unfilled bottles can withstand heat up to 120ºF (filled bottles can take even higher sustained temperatures).

Will my bottles biodegrade on store shelves, or at the end-user? PLA is compostable and biodegradable in industrial composting conditions, but it will not degrade or disintegrate on shelves. In order to degrade, PLA must be exposed to temperatures greater than 140°F and relative humidity greater than 90% for approximately 60 to 80 days.

What kind of coloring and decorating is available? PLA accepts a wide variety of colorants, and can be decorated with a variety of methods including flexographically printed 1.6mm biaxially-oriented PLA labels. As an added benefit, PLA is known to hold the details of embossing better than PET for very detailed effects.

What's the cost? Alpha Packaging predicts the cost for its PLA bottles and jars will remain very competitive to PET packaging; the bottles can be run on Alpha's existing machinery and tooling.

For more information, please speak with your Alpha Sales Representative.