Thermoplastics 101

Much has been made of the negative effects of plastics on the environment in recent years. However, what may seem obvious to specialists in the industry is not obvious to everyone. What many people don’t know are the basic properties in the different types of plastics, some of which are more environmentally friendly than others. Plastics can be categorized as Thermoplastics of Thermosets.

Thermoplastic Resins

A thermoplastic is a class of polymer that can be softened through heating and then processed using various polymer processing techniques such as extrusion, injection molding, thermoforming, and blow molding.

Thermoplastics harden once cooled and do not show any changes in chemical properties after being heated and cooled multiple times, making them easily recyclable.

Thermoplastic resins are substances that soften at high temperatures and then solidify once again at low temperatures. These characteristics allow thermoplastic materials to be molded into a wide range of forms and structures, making plastic resins useful across numerous sectors.

What are Thermoplastic Polymers?

Thermoplastic polymers are materials made up of linear molecular chains that maintain their molecular structure during melting and reshaping. These polymer chains can be melted and reformed. At elevated temperatures, thermoplastics become pliable, yielding a viscous liquid, which allows for multiple polymer processing methods. This makes them ideal for applications where they need to be molded or shaped, such as injection molding. Thermoplastics are also easier to recycle than other types of plastic, making them better for the environment. Thermoplastic polymers are a suitable substitute material used in a wide range of products, from secondary packaging to car parts.

The curing process for thermoplastics involves the pellets softening and becoming more fluid as additional heat is applied and the high heat distortion temperature increases. The curing process is completely reversible, as no chemical bonding takes place. This characteristic allows thermoplastics to be recycled without affecting the materials’ physical properties, due to their chemical resistance.

What Types of Thermoplastics are there?

There are two main structures of thermoplastic polymers: Crystalline and Amorphous.

Crystalline Structure

This type of thermoplastic has a definite and repeating 3D pattern or shape. The best examples of crystalline thermoplastics are polyethylene (PE) and polypropylene (PP).

Amorphous Structure

Amorphous thermoplastics have no definite 3D shape or pattern. The best examples of amorphous thermoplastics are polystyrene (PS) and polyvinyl chloride (PVC). Amorphous chain segments in these materials can be influenced by the addition of plasticizers to enhance flexibility and reduce brittleness, particularly in colder conditions, by increasing the mobility of the polymer chains and lowering the glass transition temperature.

What are the Most Popular Types of Thermoplastics?

The most popular types of thermoplastic polymers are:

• Polyethylene (PE)
• Polypropylene (PP)
• Polystyrene (PS)
• Polyvinyl chloride (PVC)
• Linear low density polyethylene (LLDPE): Used in producing plastic bags, shrink/stretch films, and food packaging due to its flexibility and softness.

What is the Process Behind Thermoplastics?

A thermoplastic is any plastic material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling. The molten plastic is then injected into a mold where it cools and solidifies, a process also known as injection molding. This process can be repeated multiple times, making thermoplastics ideal for applications where large quantities of the same item need to be produced, such as in mass production.

Structured polymer composites gave rise to thermoplastic composites. These materials feature a thermoplastic matrix, which prevents chemical instability. Thermoplastic composites soften and can be remolded without degrading when heated. They harden into the final shape when they cool.

What is the Purpose of Thermoplastic Materials?

Thermoplastic materials are used in a variety of applications, both industrial and consumer. Common examples include:

• Secondary packaging, such as crates
• Car parts, such as dashboards and bumpers
• Appliances, such as washing machine tubs
• Furniture, such as chairs and tables
• Heat resistant medical equipment, highlighting its use in creating durable and resilient medical products
• Manufacture moving machine parts, emphasizing its utility in producing durable components such as bearings, gears, and artificial joints

Thermoplastics are also used in 3D printing. In this process, the thermoplastic filament is extruded from a nozzle and deposited layer by layer to create a three-dimensional object.

Why are Thermoplastics Important?

Thermoplastics are important because they can be recycled repeatedly without losing quality. This makes them much more sustainable than other types of plastics, which can only be recycled a few times or not at all before they need to be disposed of. Thermoplastics are also generally less harmful to the environment and offer many benefits such as their chemical stability, which allows them to resist degradation when exposed to harsh environments like acids and high temperatures. Additionally, thermoplastics are derived from raw material like polyvinyl chloride (PVC), making them versatile for various applications in manufacturing and construction.

Sustainability

Thermoplastics offer several benefits over other materials, both in terms of their environmental friendliness and their practicality. Some of the main benefits of thermoplastics include:

1. They can be reused numerous times
2. They’re less harmful to the environment
3. They’re easy to mold and shape
4. They’re lightweight and strong
5. They are low-cost

Chemical Resistance and Stability

Thermoplastics are largely resistant to chemical attack, which makes them suitable for many process applications as well as working as a good electrical insulator. This can be beneficial for the chemical industry too.

Corrosive Environments

Thermoplastics handle corrosive materials and corrosive environments well, meaning that they provide corrosion protection.

Processing Temperature and Glass Transition Temperature

Thermoplastic materials have exceptional thermal stability and good dimensional stability, they are suitable for practically every form of fluid transport application since they can convey materials at extreme temperatures (hot or cold).

UBQ™ – A Pioneering Climate-Positive Thermoplastic 

One of the best ways to reduce the impact we have on the environment is by choosing materials that are made from sustainable and renewable resources, like UBQ™ – a bio-based thermoplastic.

UBQ™ is a sustainable plastic alternative, made from 100% mixed municipal household waste, including all organics and hard-to-recycle materials. With UBQ™, manufacturers are able to create products that positively impact our world without compromising on profitability.

UBQ™ material partially replaces or complements conventional plastics in durable and semi-durable product applications, resulting in the capture of biogenic content, the reduction of greenhouse gas emissions, and giving waste a new life.

By diverting landfill-destined waste and converting it into a valuable thermoplastic, UBQ prevents methane emissions, groundwater leaching and protects finite resources for future generations.

Advancements in Thermoplastic Technology: The Rise of Bio-Based Thermoplastics

The growing demand for sustainable materials has driven significant advancements in the field of thermoplastics, particularly in the development of bio-based alternatives. Bio-based thermoplastics are derived from renewable resources, such as plants or agricultural waste, rather than traditional fossil fuels. These materials offer the same versatility and functionality as conventional thermoplastics but with a reduced environmental impact.

The Shift Towards Bio-Based Thermoplastics

As concerns about plastic pollution and climate change intensify, industries are increasingly looking for ways to reduce their carbon footprint and reliance on non-renewable resources. Bio-based thermoplastics provide a promising solution, offering a way to maintain the benefits of traditional plastics—such as durability, flexibility, and recyclability—while significantly lowering the environmental costs associated with their production and disposal.

Bio-based thermoplastics are made from various natural sources, including:

• Polylactic Acid (PLA): Derived from fermented plant starch, typically from corn, PLA is used in applications ranging from packaging to 3D printing.
• Polyhydroxyalkanoates (PHAs): Produced by microbial fermentation of sugars or lipids, PHAs are biodegradable and used in medical devices, packaging, and agricultural products.
• Polyethylene Furanoate (PEF): Made from plant-based sugars, PEF is a potential replacement for PET (polyethylene terephthalate) in beverage bottles and other packaging materials.
• UBQ: a new bio-based thermoplastic made from mixed municipal household waste, including all organics and hard-to-recycle materials.

These bio-based alternatives are not only renewable but also often biodegradable or compostable, making them an attractive option for reducing plastic waste.

UBQ™: A Groundbreaking Bio-Based Thermoplastic Solution

Among the leaders in this field is UBQ™, a revolutionary material that represents a significant leap forward in the development of bio-based thermoplastics.

UBQ Materials’ patented technology takes mixed municipal household waste, including organic and hard-to-recycle materials and removes any metal, mineral and glass present on the processed waste and sends it to be properly recycled. 

It then breaks the organic waste into its basic building blocks, including fibers, cellulose, lignin, collagens, and sugars and bind them with the inorganic materials, reconstructing them into a new bio-based thermoplastic, UBQ™.  

The resulting composite material acts as a single homogenous material that can be replicated time and time again. 

Key Benefits of UBQ™:

• Waste Diversion: UBQ™ helps divert waste from landfills and incinerators, reducing greenhouse gas emissions and preventing groundwater contamination.
• Carbon Footprint Reduction: Adding even a small amount of UBQ to existing product formulations can power progress toward ambitious carbon neutral, or even climate positive targets. Once converted into UBQ material, the biogenic content of the organic material is also captured, thereby reducing significant greenhouse gas emissions 
• Versatility and Compatibility: UBQ™ is compatible with existing technologies such as injection molding, extrusion, compression molding, 3D printing, and rotomolding.
• Positive Environmental Impact: UBQ™ decreases the demand for conventional plastics, and the need for extracting natural resources. The UBQ production process uses zero water, generates zero effluents, combustion or emissions, and the production plan runs on certified solar energy.

Applications of UBQ™

UBQ™ is already being used by forward-thinking companies in a variety of industries:

• Automotive: In the production of car parts, UBQ™ helps automotive manufacturers meet stringent environmental standards without compromising on performance or durability.
• Consumer Goods: From household items to sustainable secondary packaging, UBQ™ is being adopted by companies looking to reduce their reliance on fossil fuels and minimize their environmental footprint.
• Construction: UBQ™ is being incorporated into pipes, flooring, decking, roofing, and many more building and construction applications. 

The Future of Bio-Based Thermoplastics

The development of bio-based thermoplastic materials  like UBQ™ is just the beginning of a broader shift towards more sustainable materials in the plastics industry.

UBQ™ represents a pioneering solution in this space, showcasing how waste can be transformed into a valuable resource that not only meets industrial needs but also contributes to a more sustainable and circular economy. As more industries adopt bio-based thermoplastics, the potential for reducing the environmental impact of plastics becomes increasingly tangible, paving the way for a cleaner, greener future.

Frequently Asked Questions about Thermoplastics

What is thermoplastic?

Thermoplastic is a type of material that softens when heated, allowing it to be molded and reshaped. It is known for its recyclability and versatility, making it a popular choice across various industries. Thermoplastics have basic properties that include being lightweight, durable, and resistant to chemicals. They are used in a wide range of applications, from packaging and automotive parts to medical devices and consumer goods.

How does thermoplastic differ from thermosetting plastic?

Thermoplastic and thermosetting plastic differ primarily in their response to heat. Thermoplastic can be reheated and reshaped multiple times, making it recyclable. In contrast, thermosetting plastic hardens permanently after being heated and molded once, which means it cannot be remolded or recycled.

What are the advantages of using thermoplastic?

Thermoplastic offers several advantages, including ease of processing, recyclability, and versatility. It can be molded into complex shapes and is available in a wide range of colors and finishes. Additionally, thermoplastic materials are generally more cost-effective and have a lower environmental impact compared to thermosetting plastics.

Are Thermoplastics Recyclable?

Thermoplastics are easily recyclable as the polymer chain does not degrade when heated. Because the chemical bonds within the chain remain intact while the weaker bonds between polymer chains break down, thermoplastics can be melted and reused repeatedly.

Are Thermoplastics Safe?

Most types of thermoplastic are safe to use as intended. However, there have been concerns raised over PVC because of the vinyl chloride monomer (VCM) that is used in production. However, modern manufacturing methods mean that the release of VCM is very low while the residual VCM left in the polymer is so low that it can’t be detected.

Are Thermoplastics Biodegradable?

Most thermoplastics are not biodegradable. However, some thermoplastics, such as poly(lactic acid) (PLA), poly (vinyl alcohol) (PVAL, PVOH) and polyhydroxyalkanoates (PHAs) are.

Are Thermoplastics Brittle?

Below their glass transition temperature (Tg), thermoplastics are brittle and deform by elastic deformation. However, when above their Tg, thermoplastics are ductile and deform mainly through plastic deformation. So, in short, thermoplastics go from brittle to ductile as they are heated through their Tg.

Can Thermoplastic be Remolded?

Thermoplastics can be remolded repeatedly by heating and then reforming them into new shapes.

Can Thermoplastic Melt?

Semi-crystalline thermoplastics melt at a particular temperature when their crystalline regions transition to a random arrangement. This melting point is different for different thermoplastics. Amorphous thermoplastics do not have an ordered structure and therefore do not melt; they have a glass transition temperature, below which the material is brittle and, as the temperature increases, the material softens and becomes more rubbery.

Can Thermoplastic be Painted?

Thermoplastics can be painted to provide a different surface finish. However, you will need to use the correct type of paint so that it doesn’t react with any polymer coating and cause discoloration and lower weather resistance. Acrylic-based paints, including spray paints, are a good option for painting thermoplastics.

Can Thermoplastics be Welded?

Thermoplastics can be welded using a variety of different techniques. You can find out more about welding thermoplastics here.