2010 R&D 100 Winner
The primary function of food packaging is to protect the quality and freshness of the product. Plastics and polymers are ideal for this purpose, but greater concern of the volume of waste produced by such packaging, as well the use of fossil fuels, has prompted companies such as Frito Lay North America, Plano, Texas, to develop greener solutions.
With the assistance of four other companies—Natureworks, Minnetonka, Minn.; SKC Films, Covington, Ga.; Toray Plastics America, North Kingstown, R.I.; and Bryce, Memphis, Tenn.—Frito Lay has introduced SunChips Compostable Packaging, a 100% compostable packaging solution for its multi-grain snack product line. The packaging is made of more than 90% polylactic acid (PLA), derived from corn, and is designed to completely biodegrade in a hot, active compost bin in 14 weeks.
Because PLA is hydrophilic and wants to absorb moisture, Frito Lay needed to also develop a high moisture barrier lamination film, applied between a metallic barrier layer and the PLA inner layer, to prevent damage to the food. It marks one of the first non-petroleum packaging products for the 1 billion lbs/year market.
Technology
Biodegradable food packaging
Developers
Frito Lay North America
Natureworks
SKC Films
Toray Plastics America
Bryce
Development Team
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| (l-r): Brad Rodgers, Ken Laverdure, Tony Knoerzer, Ashley Leidolf, Todd Fayne of Frito-Lay North America |
The SunChips Compostable Packaging Development Team:
Ken Chang, Toray Plastics America
K.S. Choi, SKS Films
Todd Fayne, Pepsico Global R&D
Tony Knoerzer, Pepsico Global R&D
Ken Laverdure Pepsico Global R&D
Ashley Leidolf
Mark Montsinger, Bryce
Jim Nangeroni, Natureworks
Brad Rodgers, Frito Lay North America
