Technoeconomic Analysis for Biodegradable and Recyclable Paper Coated with Synthetic Ionic PBAT for Packaging Application

Abstract

This study presents a technoeconomic analysis (TEA) for a novel ionic polybutylene adipate-co-terephthalate (PBAT), CPBAT, as a paper coating material, showcasing excellent water and oil resistance. This TEA determined total capital investment, operating costs, and minimum selling prices for a production capacity of 1,000 kg of CPBAT per day. The minimum selling prices of CPBAT coated on Kraft paper (CPBAT-K) and CPABT coated on starch-coated Kraft paper (CPBAT-S) are estimated to be $1.327/m2 and $1.864/m2, respectively. Additionally, the results of a sensitivity analysis show that the production of CPBAT-K and CPBAT-S is highly sensitive to the production capacity, raw material costs, energy efficiency of the coating process, reaction energy, and reaction yield. Recovery of the ionization solvent only marginally increases the selling prices of CPBAT-K and CPBAT-S, and hence, it is highly favorable. By increasing production capacity, lowering raw material costs, using energy-efficient coating machines, and partially recovering energy from reactions, the prices of CPBAT-K and CPBAT-S can be reduced to $0.588/m2 and $0.914/m2, respectively. Given that commercial polyethylene-coated paper prices range from $0.94/m2 to $1.850/m2, CPBAT-based coated papers with comparable mechanical and barrier properties along with biodegradability and recyclability are positioned as highly competitive and sustainable alternatives in the market.