Melt coating is a manufacturing process where a molten material is applied to a substrate, forming a layer of the desired thickness. It’s a popular method for producing plastic parts with a uniform coating, such as protective layers or adhesive films. Because of its versatility and efficiency, melt coating is widely used for the production of a wide range of products.

PHA is an excellent candidate to provide both oxygen and moisture barriers, or even just a water repellant layer, for example on paper coatings for food packaging and are compliant with compostability certifications.

PHA (Polyhydroxyalkanoates) is a bio-based polymer produced naturally by bacteria during their growth phase, also known as fermentation. Its environmentally friendly properties make it a compelling alternative to traditional plastics. PHA can be composted and is readily biodegradable in various environments without leaving harmful residues, like microplastics, making it a sustainable and responsible choice for plastic replacement.

While most PHA types can be processed similarly to other plastics, there are some unique characteristics to consider.

For instance, PHA has a lower melting temperature than many conventional plastics, meaning it consumes less energy. However, most PHA types also require longer cooling time, or more energy from heat to facilitate the polymer’s crystallization. Furthermore, PHA is more sensitive to moisture and high-shear rate than most other plastics, which can result in quality issues with the final product if not handled correctly within its proper processing window. Hence, it requires careful storage and preparation, like pre-drying, to ensure optimal results.

Proper melt coating of PHA requires a thorough understanding of the material and its unique properties, as well as modifications to the standard processes. However, with its environmentally friendly attributes and potential for high production speeds, PHA undoubtedly offers the potential to become a more sustainable and efficient alternative to traditional plastics. With the right knowledge, preparation, and attention to detail, the use of PHA in melt coating can be a profitable, sustainable, and responsible choice for the future of plastic production.