Photo credit: IL Corn.
Polylactic acid, commonly known as PLA or corn plastic, is gaining traction as manufacturers seek alternatives to petroleum-based plastics and respond to growing demand for sustainable materials.
PLA is a bioplastic produced primarily from field corn. While it can also be made from feedstocks such as sugarcane and sugar beet, corn accounts for more than 60% of global PLA production because of its abundant supply, established processing infrastructure and lower conversion costs.
The global PLA market is currently valued at approximately $2.01 billion and is projected to reach $4.51 billion by 2030 as demand for bio-based plastics continues to increase.
PLA production begins with harvested field corn, which contains starches, proteins, fiber and oil. During processing, the starch is separated from the rest of the kernel through milling. Enzymes then convert the starch into dextrose, a simple sugar. Microorganisms ferment the sugar into lactic acid, which is further processed into solid PLA pellets. The resulting resin can be molded into a range of products, including cups, straws, packaging materials and 3D-printing filament.
Global PLA production totals nearly 500,000 metric tons annually. With corn starch supplying about 60% of that volume, industry estimates indicate that roughly 30 million bushels of field corn are used each year for PLA manufacturing.
Supporters of PLA point to several environmental and performance advantages compared with conventional plastics. Because it is derived from renewable agricultural feedstocks, PLA can reduce dependence on fossil resources. Production also generates an estimated 68% fewer greenhouse gas emissions and requires 65% less energy than traditional plastic manufacturing processes.
PLA is biodegradable under industrial composting conditions and can break down in as little as 90 days. When incinerated, it produces non-toxic fumes. The material is also approved by the U.S. Food and Drug Administration for food-contact applications.
The material is increasingly visible in consumer and industrial markets. Common applications include disposable cups, cutlery, takeout containers and other single-use food-service products. PLA has also become the most widely used filament material in the growing 3D-printing sector.
As sustainability initiatives continue to influence packaging and manufacturing decisions, corn-based PLA is expected to play a larger role in the global plastics market while creating additional demand for agricultural feedstocks.
Source: IL Corn, "Corn to Cup: How Field Corn Becomes Plastic"