As a new foreign trade service provider driven by technological transformation and international trade, HiSiaddi has established a "1+2+3+4=1" service system and can supply raw materials of polybutylene succinate from multiple well-known original manufacturers.
As a technology-driven foreign trade enterprise, HiSiaddi has repeatedly proposed PBAT formula optimization solutions and application improvement suggestions through technological transformation cooperation with factories and precise market demand insight. The following is a consulting case of PBAT formula optimization from HiSiaddi.
Please contact HiSiaddi customer service if you need more formula optimization consulting services.
HiSiaddi implemented systematic technical rectification covering formulas, pelletizing, and end-product processing to realize stable localized substitution of domestic PBAT.
The partner Italy FreshPack Srl is located in a modern agricultural industrial park in Bologna, Italy, a leading high-end organic fruit and vegetable deep-processing enterprise in Southern Europe. Its products supply high-end Coop fresh supermarkets in Italy and organic fruit and vegetable retail chains in Switzerland, focusing on two core products: breathable fresh-keeping PBAT composite films and biodegradable fresh produce strapping films. All products comply with EU EN13432 compostable standards and EU 10/2011 food contact material regulations, with an annual PBAT raw material procurement volume of 275 tons, relying long-term on imported modified PBAT from BASF.
Affected by local European plant maintenance, year-on-year raw material price hikes, and extended import lead times up to 98 days, the client launched a localization substitution project for domestic PBAT. After initial sample screening, 68 tons of modified film-blowing grade PBAT raw materials were purchased from two domestic major PBAT manufacturers and shipped to the client’s Italian factory for production.
Severe mass defects emerged immediately after the raw materials ran on fully automatic 3-layer co-extrusion film blowing lines: uncontrolled film breathability, cracking under low-temperature cold chain bending, dense crystal points and pinholes on film surfaces, and swelling & leakage at heat-sealed areas upon contact with fruit and vegetable juice. The yield rate plummeted from 98.1% with BASF raw materials to 53.6%. Frequent equipment shutdowns disrupted automated production, risking delayed delivery penalties for signed fresh packaging orders. Losses from semi-finished goods and scrapped raw materials totaled 34,000 EUR.
The two domestic suppliers could only slightly adjust additive dosages based on existing mass production formulas. Constrained by fixed mass production line logic, they failed to fundamentally rectify defects from PBAT base resin, overall formula systems, and twin-screw pelletizing processes. Recommended by the Italian Packaging Materials Association, the client formally entrusted Shanghai HiSiaddi Technology as a third-party technical foreign trade service provider. Our polymer engineers conducted on-site sampling and defect root cause analysis, systematically resolving all technical failures from four dimensions: base resin replacement, formula reconstruction, pelletizing process technical transformation, and client-side film blowing parameter optimization. After rectification, full-load mass production was restored, and a long-term annual procurement framework was subsequently signed.
Product: Food-grade modified PBAT pellets HS Code: 3913900000 Packaging: 25kg moisture-proof kraft bags lined with aluminum foil for export
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Improper Selection of PBAT Base Resin with Inherent Molecular Structure Defects The domestic supplier adopted low-cost general polymerized PBAT substrate with high residual BDO, excessively broad molecular weight distribution, and low-molecular oligomer content as high as 340ppm—far exceeding BASF’s internal control standard of 85ppm. Small molecules volatilize during high-temperature melt extrusion, forming microbubbles inside films that turn into visible crystal points and pinholes post-processing. Meanwhile, unbalanced soft/hard segment ratios lead to insufficient molecular toughness under -18°C cold chain conditions, causing widespread cracking upon film bending—the primary root cause of strapping film breakage.
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Unreasonable Modified Formula Systems with Additives Non-Compliant for High-End Food Packaging (1) Fresh-keeping Breathable Film Formula: To cut costs, the factory added industrial-grade calcium carbonate as filler. Unactivated inorganic powder agglomerates, resulting in uneven film thickness and volatile breathability indicators. Low-cost non-food-grade lubricants cause additive migration upon contact with acidic fruit and vegetable juice, leading to swelling and leakage at heat-sealed seams, failing to meet EU 10/2011 food migration limits. (2) Strapping Special Film Formula: PBAT/PLA blending ratios were set empirically without rheological test data support. Imbalanced ratios make it impossible to balance film stiffness and elongation, causing breakage under strapping tension on fruits and vegetables. The original formula lacked food-grade anti-hydrolysis additives, accelerating film degradation and breakage under high-humidity fresh produce storage conditions.
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Extensive Twin-Screw Pelletizing Production Processes Aggravating Raw Material Performance Defects The factory shared general extrusion lines for multiple PBAT grades, causing cross-contamination between different raw materials. Fillers and additives were fed in one single bulk feed, leading to uneven dispersion of inorganic powder and tougheners inside screws. Excessively high temperatures across screw zones triggered thermal degradation of PBAT and unstable melt performance. Improper drying temperatures post-pelletizing left excessive moisture in pellets, generating pinhole defects from water vaporization during film blowing.
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Client Retained BASF Processing Parameters Mismatched with Domestic PBAT Rheological Properties All equipment settings (barrel temperature, screw speed, traction rate, die airflow) on the client’s full film blowing line were calibrated for the melt index and crystallization rate of imported BASF PBAT. Domestic modified PBAT differs significantly in melt viscosity and crystallization speed, amplifying crystal points, film rupture, and unstable breathability defects. Repeated minor equipment adjustments by the client’s process team failed to eliminate root problems.
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HiSiaddi formed a dedicated material technical team with a 20-day sample optimization timeline, coordinating upstream PBAT raw material plants and modification workshops to implement corrective measures item by item.
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Replace High-Purity PBAT Substrate to Optimize Fundamental Physical Properties at the Source We discarded the original low-cost general PBAT raw material and adopted narrow-distribution high-purity polymerized PBAT chips from a leading domestic manufacturer. This product features low residual BDO monomers and highly regular molecular chains. Raw materials were pre-dried under constant temperature to control pellet moisture content within 0.015%, and low-molecular oligomer levels were limited to 82ppm—eliminating film crystal points originating from small molecule volatilization at the source.
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Develop Separate Food-Compliant Modified Formulas for Two Product Lines, Fully Complying with EU Food Regulations ① Fresh-keeping Breathable Film: Non-compliant industrial calcium carbonate was eliminated, replaced with silane-activated food-grade ultra-fine breathable masterbatch. EU-approved plant-based plasticizers were precisely blended, and cheap non-compliant lubricants removed. The ratio of PBAT and modified components was optimized to stabilize film breathability while preventing additive migration upon immersion in oil or acidic juice, meeting heat-seal anti-swelling standards. ② Fresh Produce Strapping Film: PBAT/food-grade PLA ratios were reoptimized via multiple rheological tests, with trace compliant anti-hydrolysis additives compounded to boost film resistance to high humidity and low temperatures. Post-modification elongation at break increased to 690%, with zero cracking after 1,000 bends at -20°C. We completed 50kg lab trials and 450kg pilot samples, with specimens sent to SGS Italy laboratories for full testing of physical properties, food migration, and composting performance.
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On-Site Optimization of Complete Twin-Screw Extrusion Production Processes HiSiaddi engineers stationed at the factory guided the separation of two independent dedicated modification lines to isolate general grade production and eliminate cross-contamination of raw materials:
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· Fillers and additives were fed evenly via segmented side feeders to improve uniform dispersion of powder inside the PBAT matrix and eliminate film surface defects caused by powder agglomeration.
· Melting zone screw temperatures were lowered to avoid PBAT thermal degradation, with refined zoning temperature control: Feed zone 135~142°C, Melting zone 158~165°C, Homogenization zone 152~159°C, Die head 148°C.
· Post-pelletizing low-temperature circulating hot air drying lines were equipped to strictly control pellet moisture content and eliminate pinhole defects from water vapor during film blowing.
1. Remote Guidance for Italian Client to Optimize Film Blowing Processing Technology HiSiaddi compiled bilingual Italian-English process operation manuals and provided one-on-one remote support to the client’s process engineers for equipment parameter optimization: For fresh-keeping films, lower main machine speed and fine-tune die cooling airflow to stabilize film bubble formation and control breathability indicators. For strapping films, reduce barrel temperature and extend in-die cooling shaping time to release forming internal stress and mitigate low-temperature cracking and heat-seal leakage defects. Continuous 72-hour small-batch machine trials verified all indicators of both film types fully compliant.
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Return & Rectification of Inventory Raw Materials Enabling Smooth Production & Loss Recovery The existing 68 tons of PBAT inventory were shipped back to the factory in batches for formula and process rectification, then shipped in two batches from Shanghai Port to Bologna Port, Italy. Complete compliance test reports facilitated fast customs clearance and warehousing. After raw material deployment, the yield rate of the two core film blowing lines rebounded to 97.8%, enabling on-time delivery of fresh packaging orders for Coop supermarkets and recovering the 34,000 EUR loss from scrapped materials and potential order penalties. The comprehensive procurement price of optimized domestic PBAT dropped by 27.9% compared to imported BASF raw materials, and delivery lead time was shortened from 98 days to 35 days.
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Formal Signing of Annual Procurement Framework Three months after rectification completion, Italy FreshPack Srl signed a 260-ton annual PBAT procurement framework with HiSiaddi, locking the two finalized optimized formulas. HiSiaddi agreed to dynamically fine-tune formulas annually in response to EU regulation updates and conduct pre-delivery physical testing for every shipment. The client later entrusted HiSiaddi with full R&D for new high-barrier biodegradable packaging dedicated to organic berries.
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Overseas Market Expansion Achievements Leveraging this benchmark rectification case for Southern European high-end fresh packaging, HiSiaddi utilized the client’s local industry resources to connect with three leading organic fresh produce enterprises of equivalent scale in Spain and Portugal. We replicated the full-chain technical service model (base resin optimization + formula rectification + pelletizing technical transformation + end-user process guidance) to secure multiple batches of modified PBAT foreign trade orders, consolidating HiSiaddi’s technical service advantage in Southern Europe’s high-end biodegradable raw material market.
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Most domestic PBAT modification manufacturers target low-end domestic disposable packaging markets, prioritizing cost control in formula design and relying on fixed modification formulas and extensive extrusion processes, lacking refined formula R&D and fine-tuning capabilities matching EU mid-to-high-end fresh packaging requirements. Long-term reliance on imported raw materials has established fixed processing parameters for overseas mid-to-high-end clients, and inherent physical property differences between domestic and imported PBAT amplify mass production defects when paired with mismatched processing technology—creating compounded mass production failures.
Breaking the superficial foreign trade model limited to raw material sourcing, HiSiaddi centers on material technology to integrate the full industrial chain: upstream base resin selection, modified formula reconstruction, extrusion process technical transformation, and downstream end-user equipment debugging. We resolve mass production technical failures from root causes, eliminating the risk of production shutdown and liquidated damages for overseas clients, while deeply binding high-quality European end buyers via professional technical expertise. Amid normalized global plastic restriction policies and continuously tightened EU food contact and composting regulations, technology-empowered foreign trade constitutes the core path for domestic PBAT to steadily penetrate mid-to-high-end European packaging supply chains.
Please contact HiSiaddi customer service if you need more formula optimization consulting services.
+86-13120989737 
info@hisiaddi.com 
English
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