Investigate the Processability of Biobased Thermoplastics Used in Nonwoven Fabrics

The Covid-19 pandemic increased enormously the manufacturing and usage of face masks and other personal protective equipment (PPE), resulting in accumulation of plastic waste and, thus, causing universal environmental concerns. In addressing the issue of waste reduction and finding alternatives for fossil-based products, investigation of different biobased and biodegradable polymers plays a crucial role. This study examines the processability characteristics of three commonly used biobased polymers available in the market: biobased poly(lactic acid) (PLA), partly biobased and biodegradable poly(butylene succinate) (PBS), and biobased high-density poly(ethylene) (BioHDPE). The investigation combines substantial polymer analysis with subsequent processability trials in two different spunmelt processes, namely, meltblow (MB) and the Nanoval technology, aiming to reveal the differences and difficulties in the processing behavior and pointing out advantages and/or disadvantages of the respective polymer/technology combination. In general, the observed processability behavior and outcomes indicate that within the used processes PLA exhibits superior processability compared to PBS and BioHDPE. Both the meltblow and Nanoval processing of PLA demonstrated a consistent production of fibers and efficient uptake without any compromise on the throughput. In contrast, the processing of PBS using Nanoval required the utilization of significantly elevated temperatures, as indicated by a rheological study. Furthermore, the rheological evaluation revealed that the viscosity of BioHDPE was excessively elevated, rendering it unsuitable for effective processing by the Nanoval method. The microfibers in the PLA-based meltblown fabric had a higher surface area, explaining why the PLA fibers were able to function as a barrier and, thus, contribute to the mitigation of air permeability adjustable between 500 and 1000 l·s^–1·m^–2 and thus competitive or even superior to PP nonwovens of the same fiber diameter and base weight (1480 l·s^–1·m^–2). Overall, these results showed that PLA can be an alternative raw material for fossil-based nonwovens of PPE applying, especially, the meltblown technique.