Foamed PLA sheet “PLAiR” Technology

Features of PLAiR

Biobased foamed sheet which made a new circulation

PLA (polylactic acid), the main component of PLAiR, is made from plant sugar, and 99%* of PLAiR is derived from natural resources.

For example, when incinerated our PLAiR emits CO₂, but it will also minimize the amount of CO₂ emissions, because its raw material, the plant from which it is derived, absorbs part of it during its growth process. It can also be decomposed into water and carbon dioxide in a controlled environment such as industrial compost**.
Furthermore, it has been proven that PLAiR emits 32% less carbon dioxide than conventional polystyrene paper (PSP) during their product life cycle***.

In addition to incineration and heat recovery, we are also working on the implementing of new End of Life options such as recycling and composting.

*Biobased plastic (PLA) and biobased filler (foaming nucleating agent)
**Result verified in accordance with ISO 14855-2 at 58℃ with aerobic micro-organisms.
***Estimations by General Incorporated Association Sustainable Management Promotion Organization 〈SuMPO〉

Compostability

PLAiR made from biobased material PLA is hydrolyzed in a controlled environment* by industrial composting and will later be decomposed into water and carbon dioxide by microorganism.

Ricoh is also working on the empirical research in collaboration with partner companies and local government to increase the ways of disposal demonstrating low impacts on the environment.

These photographs are examples of experiments performed in a controlled condition with a PLAiR sample. It may differ from the actual product.

*Result verified in accordance with ISO 14855-2 at 58℃ with aerobic micro-organisms.

Ricoh‘s foaming control technology with supercritical CO₂

PLAiR made by foaming plant-derived PLA using supercritical CO₂ can be adapted to various applications by adjusting its flexibility and strength through the foaming control technology. By foaming our PLA we also succeeded in producing an effective product using less raw material.

Due to its characteristics, PLA is difficult to foam, so it was necessary to use it in combination with resins derived from fossil resources.
PLAiR utilizes supercritical CO₂ in its manufacturing process. Through the compounding process, fillers (foam nucleating agents) are evenly distributed in PLA, and the foaming takes place with the fillers as nuclei. This allowed our experts to create a lightweight and strong sheet, PLAiR.

When pressure is applied at high temperatures to CO₂, it does not condense and only its density increases, resulting in a state called a supercritical fluid with a density similar to that of a liquid.
By compounding supercritical CO₂ and filler with PLA, fillers are distributed uniformly, and the foaming takes place with the fillers as nuclei.

Thermal insulation and heat resistance