Thermoplastic starch (tps)

EXTRUTEX Thermoplastic Starch (TPS)

Thermoplastic Starch Materials for Biodegradable Plastics and Sustainable Polymer Applications

EXTRUTEX Thermoplastic Starch (TPS) is developed for manufacturers seeking starch-based polymer materials for biodegradable and compostable plastic applications. Produced by converting suitable starch into a processable thermoplastic material through controlled heat, shear, moisture management and plasticization, TPS provides an alternative material platform for selected applications traditionally served by conventional plastics.

Designed for industrial polymer processing, TPS can be formulated for film extrusion, blown film, sheet production, injection moulding, extrusion coating and blending with compatible biodegradable polymers. Its processability and final performance depend on the starch source, plasticizer system, moisture content, additives and intended application.

EXTRUTEX supports industrial customers exploring starch-based materials, customized polymer formulations and equipment solutions for the development of more resource-conscious plastic products.

1. What Is Thermoplastic Starch (TPS)?

Thermoplastic starch is a starch-based polymer material processed to behave more like a conventional thermoplastic. Native starch, commonly obtained from renewable agricultural sources such as corn, potato, tapioca or wheat, does not generally possess the melt-processing characteristics required for direct use in ordinary plastic extrusion equipment.

To produce TPS, starch is processed with suitable plasticizers, commonly including glycerol, sorbitol or other formulation-specific components. Under appropriate temperature, pressure and mechanical shear, the native granular structure is disrupted and transformed into a more continuous thermoplastic phase.

The resulting material can be processed using appropriately configured extrusion and moulding systems. Depending on the formulation, TPS may be used as a principal material, a component in a biodegradable polymer blend, or a functional starch-based phase within a compound designed for a specific end use.

TPS is not a single standardized formulation. Its mechanical properties, melt behaviour, flexibility, moisture sensitivity and degradation characteristics vary considerably with composition and processing history. Selecting the right formulation is therefore essential to achieving reliable manufacturing performance.

2. EXTRUTEX TPS Product Overview

EXTRUTEX TPS is intended for industrial customers developing starch-based materials and plastic products. Material selection can be based on the required processing method, finished-product performance, starch content, flexibility, compatibility with other polymers and applicable end-of-life requirements.

Important: The table describes the product family and possible configurations. Exact composition, starch content, pellet dimensions, moisture limits, mechanical properties, processing temperatures and certifications must be confirmed for the specific EXTRUTEX TPS grade supplied.

3. Key Characteristics of Thermoplastic Starch

3.1 Renewable Starch-Based Raw Materials

Starch can be sourced from renewable agricultural feedstocks. This makes TPS an attractive material for manufacturers investigating alternatives to fully fossil-derived polymer systems. The environmental profile of a finished product depends on agricultural practices, raw-material sourcing, formulation, manufacturing energy, transport and waste-management conditions.

3.2 Thermoplastic Processability

When correctly formulated, TPS can be processed using suitable thermoplastic manufacturing equipment. Pelletized material can be fed into compatible extruders or moulding machines, allowing industrial processors to develop products through established polymer-conversion methods.

TPS processing requires attention to moisture, thermal history, screw configuration, residence time and material flow. Excessive heat or unsuitable processing conditions may cause degradation, inconsistent melt behaviour or reduced finished-product quality.

3.3 Adjustable Flexibility

The flexibility and stiffness of TPS can be influenced by the starch source, plasticizer content and other formulation components. Different formulations may be developed for flexible film, relatively rigid moulded parts or intermediate applications. Increasing flexibility does not automatically improve strength, barrier performance or dimensional stability, so formulation trade-offs must be evaluated.

3.4 Potential for Biodegradable Polymer Blends

TPS can be combined with selected biodegradable polymers, including certain PLA, PBAT and other compatible materials, where the formulation and processing conditions permit. Blending may help balance flexibility, stiffness, processability, cost and end-use requirements.

Compatibility, dispersion, phase morphology and moisture management are important when designing these blends. A blend containing starch is not automatically biodegradable or compostable under every condition; the complete formulation and finished article must be assessed against the relevant requirements.

3.5 Formulation Flexibility

TPS formulations can be designed around the target product and conversion process. Relevant development parameters include plasticizer selection, starch content, compatibilizers, processing aids, stabilizers, mineral fillers and the inclusion of other polymers where appropriate.

Changes to any ingredient may affect mechanical properties, water sensitivity, processing stability and product cost. A controlled formulation and testing programme is recommended before commercial production.

4. Applications of EXTRUTEX TPS

4.1 Biodegradable and Compostable Packaging Development

TPS is used in the development of starch-based packaging materials, including flexible packaging and selected disposable products. Depending on the grade and formulation, it may be processed alone or blended with other polymers to obtain the necessary balance of flexibility, strength and processability.

Potential projects include packaging films, carrier bags, liners, protective packaging components and selected short-service-life products. Finished-product performance should be validated under the expected humidity, temperature, storage and handling conditions.

4.2 Film Blowing and Flexible Films

Selected TPS formulations can be investigated for blown-film extrusion. Film quality depends on melt strength, bubble stability, draw ratio, cooling conditions, thickness uniformity and the formulation's response to moisture.

For film applications, manufacturers should evaluate tensile properties, elongation, puncture resistance, tear behaviour, sealing performance and water-vapour transmission where relevant. Blends may be required to achieve the target film performance.

4.3 Bags and Liners

TPS-based blends may be suitable for developing shopping bags, refuse bags, organic-waste bags and other flexible products, subject to the grade and applicable regulations. Bag performance depends on thickness, load requirements, seam integrity, elongation and resistance to moisture during storage and use.

Products marketed as compostable must meet the requirements of the intended market and disposal route. A starch-based composition alone is not proof of certification.

4.4 Injection-Moulded Products

Appropriately designed TPS compounds can be evaluated for injection moulding of selected disposable items, accessories and non-structural components. The compound must provide suitable melt flow, filling behaviour, cooling characteristics and dimensional stability for the selected mould.

Particular attention should be given to shrinkage, brittleness, moisture uptake and the mechanical requirements of the finished component. Tooling trials and material testing are recommended before production scale-up.

4.5 Sheet Extrusion and Thermoforming Development

TPS-containing compounds may be considered for sheet extrusion and selected thermoforming projects when the formulation offers sufficient melt strength and thermal stability. Sheet uniformity, forming temperature, draw depth, cooling and demoulding behaviour should be assessed during process development.

For demanding thermoforming applications, a TPS blend may be more appropriate than an unmodified starch-based formulation.

4.6 Agriculture and Horticulture

Potential development areas include agricultural films, horticultural accessories, plant-related products and other items for which a starch-based material may offer functional or end-of-life advantages. Suitability depends on outdoor weathering, ultraviolet exposure, moisture, mechanical loads and the intended service period.

Products designed to biodegrade in soil or outdoor environments require application-specific testing. Industrial compostability should not be interpreted as proof of biodegradation in soil, freshwater or marine environments.

4.7 Biodegradable Polymer Compounding

TPS can serve as a starch-rich component in customized polymer compounds. Twin-screw compounding can help distribute ingredients and develop a controlled material morphology when the formulation, screw design and operating conditions are appropriately selected.

Compounding trials can evaluate dispersion, torque, melt pressure, material stability, pellet quality and the mechanical performance of test specimens. The objective is to develop a material that satisfies the requirements of the downstream conversion process.

5. TPS Compared with Other Bioplastic Materials

Thermoplastic starch is one option within a wider group of bio-based and biodegradable materials. It is important to distinguish the origin of a polymer from its end-of-life properties: bio-based does not automatically mean biodegradable, and biodegradable does not necessarily mean compostable in every environment.

6. Processing and Manufacturing Considerations

TPS processing requires a controlled balance between heat, mechanical energy, plasticization and moisture. The optimal conditions depend on the exact material grade and manufacturing equipment. Process settings developed for conventional polyethylene or polypropylene should not be transferred directly to TPS without validation.

6.1 Material Handling and Storage

• Store material in sealed packaging under the conditions specified by the supplier.
• Protect opened bags from excessive humidity and contamination.
• Check the material's moisture condition and follow the grade-specific drying instructions.
• Do not apply a universal drying temperature or duration without confirming the material specification.
• Use appropriate material-handling and dust-control practices.

6.2 Extrusion

Extrusion parameters should be selected according to the TPS formulation, screw geometry, throughput and target product. Barrel temperature profiles, screw speed, melt pressure and residence time need to be optimized together. Excessive thermal or mechanical energy can damage the material, while inadequate processing may result in poor dispersion or unstable flow.

Venting, feeding stability and moisture management may be particularly important. Equipment configuration should be reviewed before production trials, especially when switching from conventional resin to a starch-based compound.

6.3 Twin-Screw Compounding

Co-rotating twin-screw extruders are commonly used for developing polymer blends and compounds. Their modular screw elements can provide conveying, mixing and dispersive functions suited to the formulation. Feed strategy, screw speed, temperature profile and venting configuration should be established through technical trials.

For TPS blends, the goal is to obtain consistent ingredient distribution while avoiding excessive degradation and moisture-related instability. Pelletizing and subsequent storage must also be designed around the material's moisture sensitivity.

6.4 Quality Control

Recommended quality-control checks may include moisture content, melt flow or rheological behaviour, bulk density, pellet appearance, mechanical properties and dimensional consistency. For film products, testing can additionally cover thickness variation, tensile strength, elongation, tear resistance and sealing performance.

Testing should use appropriate methods for the intended material and application. Comparisons between grades are meaningful only when sample preparation, conditioning and test procedures are consistent.

7. Technical Properties and Testing

TPS properties vary significantly with the starch source, plasticizer content, additives and manufacturing history. EXTRUTEX customers should request the technical data sheet for the specific grade rather than relying on generic TPS values.

8. Biodegradability and Compostability

One of the main reasons manufacturers investigate TPS is its potential role in biodegradable material systems. However, biodegradation is a process governed by the material's composition and the surrounding environment. Temperature, humidity, oxygen availability, microbial activity, material thickness and the disposal system can all influence the outcome.

Industrial compostability, home compostability, biodegradation in soil and biodegradation in aquatic environments are different claims with different testing requirements. A material suitable for industrial composting is not necessarily suitable for home composting or direct disposal in nature.

For products intended for commercial sale, manufacturers should verify the relevant standards, certification scope, permitted claims and local packaging regulations. Depending on the target market, relevant frameworks may include EN 13432 for packaging recoverable through composting and biodegradation, or ASTM D6400 for plastics intended for municipal or industrial aerobic composting facilities.

Certification should be confirmed for the actual material formulation and, where required, the finished product. Pigments, inks, adhesives, fillers and other additives can affect compliance. EXTRUTEX customers should request supporting documents for the specific grade and application.

9. Benefits for Industrial Material Developers

• Starch-based material platform: Supports development work involving renewable agricultural feedstocks.
• Multiple processing opportunities: Selected formulations can be evaluated for film, sheet, moulding and compounding applications.
• Blend development: TPS can be combined with compatible polymers to target specific product requirements.
• Formulation flexibility: Plasticizers and other ingredients can be selected according to the required performance.
• Product-development potential: Suitable for manufacturers investigating alternative materials for packaging and other selected products.
• Equipment integration: Material development can be coordinated with appropriate extrusion and compounding technology.
• Application-led selection: Grade choice can be based on conversion method, target properties and applicable compliance requirements.

Actual commercial benefits depend on material price, production efficiency, formulation performance, regulatory requirements and end-of-life infrastructure. Representative production trials and a total-cost assessment are recommended before changing an established resin system.

10. EXTRUTEX TPS for B2B Customers

EXTRUTEX serves industrial customers looking for polymer materials and processing solutions for specialized manufacturing applications. Thermoplastic starch projects often require coordination between raw-material selection, compounding, downstream conversion and finished-product testing.

EXTRUTEX brings an Austria-led design, laboratory and research-and-development approach together with manufacturing in China. For TPS-related projects, customers can discuss the intended application, material formulation requirements and suitable processing technology with the team.

Whether the objective is developing flexible packaging, investigating a starch-based compound or evaluating a new extrusion process, clear technical requirements help establish the most appropriate development route.

11. How to Select the Right TPS Grade

Before choosing a thermoplastic starch material, manufacturers should define the finished product and its working environment. A film used for dry goods packaging, for example, may require different properties from a bag exposed to humid conditions or a moulded part that must retain its shape during storage.

1. Define the end product: Identify the product type, dimensions, thickness and intended service life.
2. Choose the processing method: Specify blown film, cast film, sheet extrusion, injection moulding or compounding.
3. Set performance targets: Establish required strength, elongation, flexibility, moisture resistance and appearance.
4. Confirm material compatibility: Identify whether pure TPS or a blend with PLA, PBAT or another polymer is being considered.
5. Specify the end-of-life route: Determine whether biodegradation, industrial compostability or another waste-management outcome is required.
6. Review compliance: Confirm the standards and certifications required in the target market.
7. Conduct production trials: Validate processing stability, product quality, throughput and total manufacturing cost.

12. Frequently Asked Questions About EXTRUTEX TPS

What does TPS stand for?

TPS stands for Thermoplastic Starch. It is a starch-based material that has been formulated and processed to enable thermoplastic conversion methods such as extrusion or moulding.

Is thermoplastic starch biodegradable?

TPS is generally investigated for biodegradable material applications, but actual biodegradation depends on its complete formulation and the environment. A finished product should be tested against the appropriate standard before making a specific biodegradability or compostability claim.

Can TPS be used for blown film extrusion?

Yes, selected TPS grades and blends can be developed for blown film. Bubble stability, melt strength, moisture management and mechanical properties should be confirmed through trials with the intended equipment.

Can TPS be blended with PLA or PBAT?

TPS can be compounded with selected PLA, PBAT and other compatible polymers. The best blend depends on the required flexibility, strength, processing characteristics and applicable end-of-life criteria.

Is TPS suitable for injection moulding?

Selected TPS formulations can be evaluated for injection moulding. Melt flow, cooling behaviour, shrinkage, moisture sensitivity and the mechanical requirements of the finished part must be considered.

Does TPS absorb moisture?

TPS is generally more sensitive to moisture than many conventional commodity plastics. The degree of moisture sensitivity depends on its composition, plasticizer system and processing history. Appropriate storage, packaging and application testing are important.

Can TPS replace conventional PE or PP?

TPS can be considered as an alternative or blend component in selected applications, but it is not a universal drop-in replacement for polyethylene or polypropylene. Material performance, processing settings, service conditions and disposal requirements must be evaluated for each product.

What packaging sizes are available?

Packaging format and net weight should be confirmed with EXTRUTEX for the selected grade and order quantity. Please request the current packaging specification before placing an order.

Can EXTRUTEX support customized material projects?

Customers can discuss their target product, processing method and performance requirements with EXTRUTEX to determine suitable material and equipment-development options.

13. Request Information About EXTRUTEX Thermoplastic Starch

If your company is developing biodegradable packaging, starch-based polymer compounds, flexible films or other thermoplastic products, contact EXTRUTEX to discuss TPS material selection and processing requirements.

To help identify a suitable solution, please provide the intended application, processing equipment, target product properties, estimated annual consumption and any certification requirements. This information helps determine which material specifications and development trials are appropriate for your project.

EXTRUTEX Thermoplastic Starch (TPS)

Explore starch-based material solutions for industrial polymer processing and biodegradable product development.

Contact EXTRUTEX for grade specifications, technical data, samples and project discussions.

Ask our team about TPS formulations, biodegradable polymer blends, extrusion processing and compounding technology.