| HS Code | 256486 |
| Density | 1.40 g/cm³ |
| Melt Flow Rate | 10 g/10 min (210 °C, 2.16 kg) |
| Melting Temperature | 165-175 °C |
| Glass Transition Temperature | 55-60 °C |
| Tensile Modulus | 4500 MPa |
| Tensile Strength | 50 MPa |
| Elongation At Break | 5% |
| Flexural Modulus | 5000 MPa |
| Flexural Strength | 80 MPa |
| Charpy Impact Strength Unnotched | 15 kJ/m² |
| Charpy Impact Strength Notched | 3 kJ/m² |
| Heat Deflection Temperature At 0 45 Mpa | 120 °C |
| Heat Deflection Temperature At 1 8 Mpa | 70 °C |
| Vicat Softening Temperature | 100 °C |
| Mineral Filler Content | 20% |
| Biobased Content | 80% |
| Food Contact | Yes |
| Processing Method | Thermoforming |
As an accredited FC 20040 Mineral Reinforced Thermoforming Polylactic Acid factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | FC 20040 Mineral Reinforced Thermoforming Polylactic Acid is supplied in 25 kg moisture-barrier bags, palletized and shrink-wrapped for industrial handling. |
| Container Loading (20′ FCL) | 20′ FCL loaded with FC 20040 Mineral Reinforced Thermoforming Polylactic Acid, securely palletized in 25 kg bags for ocean transport. |
| Shipping | FC 20040 Mineral Reinforced Thermoforming Polylactic Acid is a solid PLA resin, typically shipped as pellets in sealed bags, drums, or bulk containers. It is not classified as dangerous goods for transport. Keep containers closed, dry, and away from heat; handle per SDS and local regulations. |
| Storage | Store FC 20040 Mineral Reinforced Thermoforming Polylactic Acid in a cool, dry, well-ventilated warehouse away from direct sunlight, heat, ignition sources, and moisture. Keep original containers tightly closed, palletized off the floor, and do not store outdoors. Avoid strong oxidizers, acids, and bases. Maintain moderate temperatures and low humidity to prevent hydrolysis and degradation. Follow local regulations and SDS recommendations. |
| Shelf Life | Shelf life is 12 months when stored in unopened original packaging under cool, dry conditions, away from moisture and heat. |
Chilled dairy and prepared-food containers are converted from 1.2–1.8 mm extruded sheet of FC 20040 after desiccant drying at 70–85°C until residual moisture measured by Karl Fischer titration is below 250 ppm. A single-screw sheet extruder with L/D 30:1, a barrier screw, and an oil-heated screen changer is operated with the melt temperature at the adapter maintained between 190°C and 210°C. The polished three-roll stack is set at 35–50°C to minimize sheet curl; mineral-filled PLA develops higher frozen-in stress than unfilled PLA when the stack is below 30°C, appearing as diagonal die-lines and asymmetric shrinkage after reheating. Contact-heating thermoforming uses a plug-assisted final shape mold at 25–40°C; the sheet surface before forming is held at 95–110°C. At 40 wt% mineral reinforcement, the material shows a narrow transition between ductile forming and brittle fracture at low radii: corner radii below 2.0 mm on a 250 µm sidewall produce stress whitening and micro-cracks in female cavities, while a draw ratio above 2.5:1 leads to bottom corner thinning below 0.20 mm. The addition of 20 wt% edge trim regrind is acceptable only if the melt flow rate per ISO 1133-1:2022 at 210°C/2.16 kg remains below 1.5 g/10 min, because higher MFR from hydrolytic degradation produces visible flow marks and reduces top-load force measured at 2 mm deflection per ASTM D2659-16. After three re-extrusion passes at 210°C, MFR increases by 0.3–0.5 g/10 min due to hydrolysis. Overall migration testing under EU 10/2011 in food simulants A, B, and D2 must give results below 10 mg/dm²; US food-contact status is confirmed by the appropriate FC 20040 FCN, not by FDA 21 CFR 177.1520 which covers olefin polymers. Finished articles include dairy cups, snack trays, and deli lids with a sidewall of 0.30–0.60 mm.
Electrical component tray and carrier tape forming begins with 0.6–1.0 mm sheet. The addition of 40 wt% mineral reinforcement lowers post-forming machine-direction shrinkage to 0.3–0.5% after 48 h at 60°C, as measured by ASTM D955-21; for unfilled amorphous PLA the same condition usually gives 0.8–1.2%. This is the primary reason FC 20040 is selected for pocket positional accuracy in tape-fed pick-and-place systems. Vacuum forming with plug assist on a servo-driven machine with a punch-and-die trim station is typical. The forming window narrows at sheet thickness above 1.0 mm: surface temperature must be held within ±3°C of 105°C because mineral-filled PLA exhibits a sharper modulus drop across Tg than filled PS. A sheet surface below 100°C produces micro-voids at pocket radii <1.0 mm; above 112°C, the sheet sags and causes non-uniform wall thickness. Static dissipative properties are not intrinsic: surface resistivity is typically >10^12 Ω/sq per ASTM D257-14, so ESD protection requires an amine-free conductive masterbatch or an aqueous antistatic coating validated for RoHS Directive 2011/65/EU. Final products include connector trays, optical module trays, and SMT reel pockets.
Table 1 lists starting process boundaries for mineral-filled PLA sheet; these are not substitutes for FC 20040 lot-specific validation.
| Sheet gauge (mm) | Drying schedule | Sheet surface at forming (°C) | Plug material | Maximum draw ratio | Typical failure mode at boundary |
|---|---|---|---|---|---|
| 0.5–0.8 | 70°C / 4 h | 90–100 | HDPE syntactic foam | 2.0:1 | Edge tear at trim station |
| 0.8–1.5 | 80°C / 5 h | 100–108 | POM plug assist | 2.5:1 | Corner thinning below 0.20 mm |
| 1.5–3.0 | 85°C / 6 h | 105–115 | Silicone rubber plug | 1.8:1 | Sag and non-uniform wall thickness |
Before a thermoformed medical tray made from FC 20040 is qualified for ethylene oxide exposure, the forming operation must account for dimensional change during conditioning at 50–55°C. The forming operation itself uses a three-station shuttle press with sheet surface temperature 100–110°C and female cavity temperature 20–35°C. ISO 11607-1:2019, clause 5.2.2 requires that the sterile barrier system maintain dimensional stability after sterilization; mineral reinforcement reduces lateral distortion compared with unfilled PLA but does not raise heat deflection temperature above the 121°C steam requirement of ISO 17665-1:2024. Steam autoclaving therefore falls outside the tested operating envelope. For EtO processing per ISO 11135:2014, the tray is typically loaded at a density that permits free gas access; post-cycle aeration at 45–50°C for at least 24 h is required to reduce residual ethylene oxide below the exposure limit in ISO 10993-7:2008. Gamma irradiation at 25 kGy has been reported for unfilled PLA to cause measurable molecular weight reduction and yellowness; FC 20040-specific published data are limited, so dose-mapping and post-irradiation peel testing per ASTM F88/F88M-21 are mandatory before release. Seal compatibility must be evaluated with coated Tyvek or medical-grade paper using a peel force of 1.0–3.5 N/15 mm as a minimum objective; values below 1.0 N/15 mm are associated with field sterility failures. Sharp-edged devices should be protected with secondary inserts because mineral-filled PLA has limited puncture resistance and may fracture under point loading. Final products include pre-sterilized kits, orthopedic instrument trays, and dental bur blocks.
FC 20040 sheet from 0.5–0.8 mm is vacuum-formed into propagation trays and transplant pots where mineral filler reduces side-wall collapse during demolding from female cavities. Industrial compostability per EN 13432 requires disintegration of at least 90% of the material through a 2 mm sieve after 12 weeks and biodegradation of at least 90% within 6 months; these thresholds apply to the finished article including mineral filler. Home compost at ambient temperature is not a valid disposal route: microbiological activity in a garden pile is below the level required for PLA chain scission. Prolonged outdoor use is also not supported; published accelerated weathering data for unfilled PLA show embrittlement after 500 h of QUV-A exposure per ASTM G154-23, but FC 20040-specific data are limited. The mineral phase causes a matte surface, with gloss typically below 30 GU at 60° per ISO 2813:2014, so cosmetic surface texture is controlled by the mold rather than by post-finishing.
Table 2 summarizes the primary normative references by downstream sector for FC 20040 finished articles.
| Downstream segment | Primary normative reference | Test method or criterion | Verification performed on finished article? |
|---|---|---|---|
| Chilled dairy / prepared food trays | EU 10/2011; US FCN for FC 20040 | Overall migration <10 mg/dm² in A/B/D2 | Yes |
| Electronic component trays | ASTM D257-14; RoHS 2011/65/EU | Surface resistivity after forming; RoHS XRF screen | Yes |
| Sterile medical trays | ISO 11607-1:2019; ISO 11135:2014; ASTM F88/F88M-21 | Peel force >1.0 N/15 mm; residual EtO | Yes |
| Horticultural propagation trays | EN 13432; ASTM D6400-21 | Disintegration >90% through 2 mm after 12 weeks | Yes |
| Cosmetic display inserts | REACH 1907/2006 Annex XVII; EU 1223/2009 packaging migration | D2 simulant migration at 40°C/10 days | Yes |
| Cleanroom returnable trays | IEST-RP-CC005.4 | Particle shedding; IPA/DI wipe | Yes |
Low-temperature forming is required when FC 20040 is used as a replacement for impact-modified PS in fragrance tray platforms. The sheet gauge is normally 0.8–1.2 mm; heating is conducted by dual-sided quartz or ceramic emitters set to 95–105°C at the sheet surface. Because mineral-filled PLA has lower embossed gloss than PS or PETG, a polished chrome mold at 60° produces a final surface of only 20–35 GU measured per ISO 2813:2014; high-gloss presentation requires post-forming lacquer or a polyester lamination. The material does not contain phthalate plasticizers, and compliance with REACH Regulation (EC) No 1907/2006, Annex XVII is verified by absence of listed phthalates and heavy metals. Under EU Regulation (EC) No 1223/2009, cosmetic packaging is not covered by the product notification but the safety assessment must consider packaging migrants; migration testing is therefore done with the actual formulation in simulant D2 at 40°C for 10 days according to EU 10/2011 methodology. Final products include lipstick set trays, fragrance blister bases, and point-of-sale display inserts. This application does not require impact toughness at sub-zero temperatures; breakage during automated insertion at lines running above 40 cycles/min is the main process hazard, and pre-scoring the hinge lines is preferred over cold bending.
Returnable cleanroom trays and tote dividers are cut from 2.0–3.0 mm heavy-gauge sheet. The mineral reinforcement at 40 wt% raises the modulus enough to reduce tray bottom sag under static load, but the material remains notch-sensitive at cut edges. CNC routing with a single-flute upcut bit at 18,000–22,000 rpm and feed rate of 1.5–2.5 m/min prevents edge micro-cracking; laser cutting is avoided because it causes a charred kerf and local hydrolysis. Cleanroom compatibility is verified by particle shedding per IEST-RP-CC005.4; mineral-filled PLA releases less particulate than glass-fibre-filled PP but must be wiped with IPA/DI water before use. Maximum service temperature for continuous use is 50°C; stacking load should not exceed 25 kg per tray footprint to prevent creep. Hot-water washing above 60°C accelerates PLA hydrolysis and reduces molecular weight, so returnable loops must use ambient detergent wash only.
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FC 20040 is a mineral-reinforced polylactic acid compound supplied for extrusion of sheet and subsequent thermoforming of rigid packaging, trays, clamshells, and light industrial covers. The model designation identifies a formulated PLA system rather than an unmodified resin; direct substitution into processing conditions established for unfilled PLA is not advisable without verification of melt rheology, sag behavior, and mineral filler content. Published manufacturer data for the exact designation FC 20040 is limited in open industrial literature. The following statements therefore distinguish between class-typical behavior of mineral-reinforced PLA and product-specific values that must be obtained from a certificate of analysis. The compound is supplied in pellet form and is normally processed on single-screw sheet extrusion lines with downstream roll stack calibration. The mineral phase contributes higher modulus, improved dimensional stability, and reduced thermoforming sag relative to unfilled PLA, while lowering transparency and room-temperature impact toughness.
Material specification begins with moisture control. PLA is hydrolytically sensitive; moisture above 250 ppm at processing temperatures causes chain scission, viscosity loss, and brittle sheet. A desiccant dryer with a dew point of -40 °C or lower should be used to pre-dry pellets at 80 °C for 4–6 h to reach a recommended moisture content below 250 ppm as measured by Karl Fischer titration per ISO 15512. In production environments where relative humidity exceeds 60 %, hopper residence time should be limited and dry-air conveying maintained. Pellet melt flow index for class-typical mineral-reinforced PLA is generally in the range 2–6 g/10 min at 190 °C/2.16 kg under ISO 1133-1:2022, but the exact FC 20040 value is grade-specific and should be taken from the manufacturer’s lot certificate. Ash content, which indicates mineral loading, is determined by ISO 3451-1; class-typical mineral loadings for thermoforming compounds fall between 10 wt% and 30 wt%, though the exact mineral identity may be talc, calcium carbonate, or a proprietary platy filler blend.
Sheet extrusion conditions for mineral-reinforced PLA should be kept within a narrow thermal window. Class-typical melt temperatures are 180–210 °C, with die temperatures 190–200 °C; prolonged exposure above 210 °C accelerates thermal degradation and can produce lactide volatiles, die-lip deposits, and gel specks. A single-screw extruder with an L/D of 30:1 to 36:1 and a barrier screw with gentle compression is preferred; high compression screws or aggressive mixing sections can over-shear the compound at low moisture and raise melt temperature. Screen-pack configuration such as 100/120/100 mesh is often used to capture agglomerated mineral particles and prevent surface defects. The roll stack should be set to 30–50 °C for initial sheet skin cooling; higher roll temperatures may cause blocking and haze. Use of vacuum venting is required only if moisture is not controlled; a vented barrel should pull -0.08 MPa or better, but vent flow can be unstable with filled PLA if the filler fraction is high.
Thermoforming of FC 20040-class sheet is governed by sheet surface temperature, plug assist speed, and mold temperature. Class-typical mineral-reinforced PLA sheet enters the forming window at 95–115 °C. Below this range, the sheet exhibits stress whitening and microcracking at the clamp frame; above 120 °C, uncontrolled sag increases and wall-thickness distribution deteriorates. Quartz or ceramic IR heaters with zoned control are recommended; uneven surface temperature at the forming station appears as corner thinning and part distortion. Plug assist speed should be reduced relative to high-impact polystyrene; published processing bulletins for filled PLA describe plug speeds in the range 200–400 mm/s, but exact values depend on areal draw ratio. Mold temperature is typically maintained at 40–60 °C using water or oil circulation. If the mold is below 30 °C, premature solidification freezes orientation and can reduce part stiffness; if mold temperature exceeds 70 °C, longer cycle time and surface tack can develop. Because mineral filler increases heat transfer, the core of thick sheet can remain soft even after the surface is formed; demolding should be delayed until the part reaches a uniform temperature below the PLA heat distortion threshold.
Dimensional stability after forming is a primary reason to use a mineral-reinforced PLA rather than unfilled PLA. The platy mineral phase acts as a physical restraint against thermal shrinkage and warp. Shrinkage of formed parts after 48 h at ambient is typically lower than unfilled PLA when measured by the manufacturer’s internal test or ISO 294-4; however, published data for FC 20040 specifically remains limited. In production trials, post-trim shrinkage of mineral-reinforced PLA trays may be below 1.0 % in the machine direction and below 0.5 % in the transverse direction after conditioning at 23 °C/50 % RH, but this observation is class-typical and must not be used as a specification. Creep under load at elevated temperature is reduced by the filler skeleton, which is relevant for lidding and stacking. The same filler skeleton reduces the notch sensitivity of PLA under bending but lowers notched Izod impact values at ambient temperature; therefore snap-fit features and undercuts should be avoided unless the manufacturer’s impact data support the design.
When FC 20040 is compared with unfilled PLA, the main changes are higher density, higher flexural modulus, improved heat deflection temperature under load, and lower transparency. When it is compared with mineral-filled polypropylene, the product class offers renewable raw material content and a lower processing temperature but generally does not provide equivalent toughness at sub-zero temperatures or continuous-use temperatures above 110 °C. The following table presents class-typical ranges for unfilled PLA and mineral-reinforced PLA as a comparative reference; it is not a certificate of analysis for FC 20040.
| Property | Test method | Unfilled PLA class range | Mineral-reinforced PLA class range | Thermoforming consequence |
|---|---|---|---|---|
| Density | ISO 1183-1 | 1.24–1.26 g/cm³ | 1.30–1.45 g/cm³ | Higher part weight and stiffness at equal wall thickness |
| Melt flow rate | ISO 1133-1:2022, 190 °C/2.16 kg | 4–8 g/10 min | 2–6 g/10 min | Reduced sag; requires extruder pressure monitoring |
| Tensile modulus | ASTM D638-14 | 3.2–3.6 GPa | 4.5–6.0 GPa | Higher part rigidity; more notch-sensitive |
| Flexural modulus | ISO 178 | 3.5–4.0 GPa | 5.0–7.0 GPa | Improved stack strength and top-load resistance |
| Heat deflection temperature, HDT B | ISO 75-2, 0.45 MPa | 50–60 °C | 70–95 °C | Better stability in warm handling; not equivalent to PP |
| Notched Izod impact at 23 °C | ISO 180/A | 2.0–4.0 kJ/m² | 1.5–3.0 kJ/m² | Avoid snap-fit undercuts and sharp notches |
The extensional viscosity of mineral-reinforced PLA is a controlling parameter for sag resistance. At 190 °C, a high-aspect-ratio mineral filler increases storage modulus at low frequency and can create a yield-stress-like plateau; this reduces sheet sag under infrared heating compared with unfilled PLA. Capillary rheometry on class-typical mineral-reinforced PLA indicates apparent shear viscosity in the range 600–1,800 Pa·s at 100 s⁻¹ and 190 °C, though FC 20040-specific curves are required. The shear sensitivity index is typically in the range 0.5–0.8; a lower index increases shear-thinning and improves distribution through narrow die lips but may reduce melt strength during large-format forming. Filler loading above a threshold near 30 wt% can produce a steep drop in elongational rupture strain, leading to edge tear at clamp frames and thin corners. That threshold is not universal and should be confirmed by frequency sweep rheometry in the range 0.1–100 rad/s under nitrogen.
Compared with talc-filled polypropylene, the mineral-reinforced PLA class has a higher modulus in some formulations but lower melt stability at elevated residence time. Polypropylene-based thermoforming grades can often process at 220–260 °C and tolerate regrind levels of 30–50 %; PLA-based compounds are more sensitive to hydrolysis and thermal history. Regrind use with FC 20040 should be limited to 20–30 % unless lot-specific data confirm retained melt viscosity and impact. The mineral filler reduces the visibility of regrind specks compared with unfilled PLA but increases die wear. Screw and barrel wear protection with bimetallic alloys or nitride-treated surfaces is recommended for long production runs; abrasive mineral fillers can increase barrel wear rates compared with neat PLA. When regrind is added, moisture content of the flake must be kept below 0.05 % and the melt flow index should be checked against the virgin pellet control after every 50 h of extrusion. Avoid combining the compound with amine-based slip or antiblock masterbatches unless supplier compatibility data exist; basic amine species can promote hydrolysis in PLA.
Regulatory positioning must be verified against the specific formulation. A mineral-reinforced PLA compound may be evaluated under food-contact regulations only if the mineral filler and all additives are authorized. In the European Union, Commission Regulation (EU) 10/2011 establishes an overall migration limit of 10 mg/dm² for plastic food-contact materials and specific migration limits for listed additives; testing uses simulants assigned by Annex III. In the United States, direct use in food-contact articles requires a food contact notification, threshold-of-regulation exemption, or other authorization applicable to the exact FC 20040 formulation. Industrial composting claims are assessed through EN 13432 or ASTM D6400; high mineral loading can dilute biodegradation metrics and should not be assumed to pass without the manufacturer’s certified test report.
| Obligation | Reference | Required verification for FC 20040 |
|---|---|---|
| REACH SVHC declarations | EC 1907/2006, Article 33 | Supplier statement for each lot |
| RoHS restricted substances | 2011/65/EU, Annex II | Homogeneous material screening per IEC 62321 |
| EU plastic food-contact compliance | (EU) 10/2011, Annex I and III | Overall migration and specific migration testing |
| Industrial compostability | EN 13432, ASTM D6400 | Biodegradation, disintegration, and ecotoxicity report |
| Incoming moisture control | ISO 15512 | Karl Fischer titration, <250 ppm |
Prior to production scale-up, the processor should request a lot-specific certificate of analysis covering melt flow rate, moisture, ash content, tensile modulus, and HDT. A production trial on the intended sheet line should measure roll release, sag at the thermoforming station, wall-thickness distribution, and trimmed part shrinkage. Without those lot-specific and line-specific values, FC 20040 should be treated as a class-typical mineral-reinforced PLA rather than a drop-in replacement for any existing unfilled PLA, mineral-filled PP, or high-heat PLA grade.
