| HS Code | 747691 |
| Product Name | PHACT™ CA1240PF Blown/Cast Film Polylactic Acid-aPHA Calcium Compound |
| Chemical Family | Polylactic Acid (PLA) / amorphous Polyhydroxyalkanoate (aPHA) / Calcium Compound |
| Form | Pellets |
| Color | Off-white |
| Density | 1.25-1.30 g/cm³ |
| Melt Flow Rate | 2.5-4.0 g/10 min at 190°C/2.16 kg |
| Melting Point | 145-155°C |
| Glass Transition Temperature | 50-60°C |
| Tensile Strength | 20-30 MPa |
| Elongation At Break | 200-400% |
| Flexural Modulus | 1000-1500 MPa |
| Biobased Content | ≥70% |
| Compostability | Industrial compostable (ASTM D6400, EN 13432) |
| Processing Method | Blown film, Cast film |
| Moisture Content | <0.5% |
As an accredited PHACT™ CA1240PF Blown/Cast Film Polylactic Acid-aPHA Calcium Compound factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | PHACT™ CA1240PF is packaged in 25 kg net-weight polyethylene-lined fiber drums, palletized and stretch-wrapped for secure transport. |
| Container Loading (20′ FCL) | PHACT™ CA1240PF Blown/Cast Film Polylactic Acid-aPHA Calcium Compound in 20′ FCL: palletized, stretch-wrapped, moisture-protected, strapped, braced, non-hazardous, dry-container loading. |
| Shipping | PHACT™ CA1240PF is shipped as a non-hazardous, non-regulated solid polymer compound, typically in moisture-barrier bags, supersacks, or drums on pallets. Maintain dry conditions, avoid excessive heat/moisture, and use standard freight. No UN number, hazard class, or special transport permits required. |
| Storage | Store PHACT™ CA1240PF Blown/Cast Film Polylactic Acid-aPHA Calcium Compound in a cool, dry, well-ventilated area, away from direct sunlight, heat, and ignition sources. Keep containers sealed to prevent moisture absorption and contamination. Maintain ambient temperature, avoid excessive stacking, and rotate stock using first-in, first-out. Keep separate from incompatible materials. Protect from physical damage. Follow supplier’s shelf-life and handling recommendations. |
| Shelf Life | Shelf life is 12 months stored in unopened packaging in a cool, dry place, away from moisture and direct sunlight. |
A mono-layer blown film for high-turnover retail carrier bags imposes simultaneous constraints on melt strength, dart impact resistance, seal initiation temperature, and continuous roll-to-roll output. In this application, PHACT™ CA1240PF is incorporated at 20 wt% to 40 wt% of the total polymer phase in a PLA-rich matrix, while the remaining fraction is neat PLA and a small addition of slip/antiblock masterbatch. Published data for this specific configuration is limited; production trials on 50 mm to 65 mm single-screw extruders with 28:1 to 33:1 L/D indicate that the lower bound is set by processability, and the upper bound is governed by bubble stability because the calcium carbonate filler phase reduces elongational viscosity at the freeze line. Pre-drying at 70 °C for 4 h to a moisture content below 250 ppm is required when warehouse RH exceeds 60%; undried material produces hydrolytic chain scission and measurable loss of melt strength at the die lip.
Compostability certification for carrier bag films follows EN 13432:2000/AC:2005 clause 4.2.2 for lab-scale disintegration, ISO 14855-2:2018 for ultimate aerobic biodegradation with a 90% mineralization threshold within 180 days, and ASTM D6400-21 for North American municipal or industrial composting. Mechanical property verification is conducted under ISO 527-3:2018 at 500 mm/min and Elmendorf tear per ASTM D1922-15a; film thickness is checked by ISO 4593:1993. The blown film tower uses a die gap of 0.9 mm to 1.2 mm, blow-up ratio 3.0:1 to 3.8:1, and frost line height 250 mm to 350 mm above the die face. Melt temperature at the die is held between 168 °C and 182 °C; higher settings cause aPHA phase discoloration and lower settings raise die pressure beyond 18 MPa. Screw speeds from 45 rpm to 70 rpm yield throughputs of 35 kg/h to 55 kg/h on a 55 mm extruder. At loading above 40 wt%, the bubble transitions from stable tubular geometry to helical oscillation; the corrective action is either raising the frost line or reducing the calcium compound fraction, not increasing melt temperature. The terminal product is a vest-type carrier bag at 18 µm to 35 µm thickness, converted on inline bottom-seal or side-weld bag machines with heat-seal jaw temperatures of 110 °C to 135 °C.
In organic waste caddy liner production, the film operates under more severe pinhole and flex-crack stress than conventional carrier film because filled wet organic waste creates localized puncture at the base seal and within the gusset fold. The compound is metered at 15 wt% to 30 wt% in a coextruded structure, most often in the outer layers of an A/B/A three-layer stack where the core carries post-industrial regrind. Above 30 wt%, dart drop impact performance of 15 µm film falls below the operating threshold when wet food waste exerts irregular point loading; below 15 wt%, the antiblocking contribution of the calcium phase is insufficient for roll unwind after warehouse storage at 35 °C. Compliance is assessed under EN 13432:2000/AC:2005 for disintegration and ISO 17088:2021 for overall compostability, with AS 4736:2006 specified where Australian municipal or commercial composting certification is required. Mineral content restrictions set by local organic waste programs require total calcium carbonate content to be quantified by ISO 3451-1:2019 ash residue method. The film is produced on a three-layer blown film line with die gap 0.8 mm to 1.0 mm, blow-up ratio 3.0:1 to 3.5:1, and die melt temperature 158 °C to 168 °C for PBAT-rich outer layers. The film is gusseted in-line and wound on surface-center winders with taper tension of 0.3 N/mm to 0.5 N/mm. Terminal product types are caddy liners of 8 L, 15 L, and 25 L capacities at 12 µm to 20 µm, supplied as star-sealed or drawstring tie formats.
| Application | Primary standard | Critical threshold | Supporting test method |
| Retail carrier bag | EN 13432:2000/AC:2005 | 90% mineralization in 180 days | ISO 14855-2:2018 |
| Organic caddy liner | EN 13432:2000/AC:2005 | disintegration 90% in 84 days | AS 4736:2006 |
| Cast lamination to paper | EU Regulation (EU) No 10/2011 | overall migration 10 mg/dm² | EN 1186-1:2002 |
| Agricultural mulch | EN 17033:2018 | soil biodegradation 90% in 24 months | ISO 17556:2019 |
| Produce roll bag | EU Regulation (EU) No 10/2011 | overall migration 10 mg/dm² | EN 1186-1:2002 |
In paper-based compostable mailer structures, the cast lamination layer functions as both moisture barrier and heat-seal medium, replacing non-compostable solvent-borne adhesives. PHACT™ CA1240PF is let down at 10 wt% to 25 wt% in a PLA- or PLA/aPHA-rich cast film layer, depending on target seal initiation temperature and hot-tack window. Cast-grade material is qualified by melt flow rate under ISO 1133-1:2022 at 190 °C/2.16 kg, with an accepted range of 6 g/10 min to 12 g/10 min. The calcium carbonate phase shifts the melt rheology enough to permit slot-die extrusion at 170 °C to 190 °C, but above 25 wt% the cast web loses homogeneity at thin gauges because filler agglomerates create visible streak defects across the die width. For food-contact-adjacent structures, EU compliance is evaluated under EU Regulation (EU) No 10/2011 as amended by (EU) 2020/1245, with overall migration below 10 mg/dm² using EN 1186-1:2002 and specific migration methods from EN 13130-1:2004. In the United States, food-contact status is established under existing PLA food-contact notifications; documentation must be verified before use in direct food contact because 21 CFR 177.1520 does not automatically cover this compounded structure. Manufacture typically employs a cast film line with a 1.6 m to 2.4 m slot die, die gap 0.5 mm to 0.8 mm, air gap 100 mm to 180 mm, ozone treatment 2.0 kW to 4.0 kW, and chill roll surface temperature 18 °C to 24 °C. Lamination nip pressure is set between 2.5 N/mm and 4.0 N/mm, with corona treatment bringing film surface energy to 38 mN/m to 42 mN/m before paper lamination. Terminal product types include compostable paper mailers, paper-based sachets for dry goods, and padded mailer laminates where starch-foam or shredded paper cushioning is encapsulated.
Because field-deployed mulch films in 10 µm to 25 µm thickness fail most often by tear propagation along planting-hole perforations rather than by uniform tensile overload, the addition level of PHACT™ CA1240PF must be constrained by transverse direction Elmendorf tear measured per ASTM D1922-15a. The compound is incorporated at 10 wt% to 30 wt% in a soil-biodegradable mulch formulation, with carbon black masterbatch added separately at 3 wt% to 6 wt%. Concentrations above 30 wt% reduce transverse direction tear resistance to the point where mechanical laying equipment punctures the film at drawbar speeds above 5 km/h; below 10 wt%, the film lacks sufficient stiffness and calcium carbonate nucleating action for consistent cast roll release. Compliance follows EN 17033:2018, which requires ultimate soil biodegradation of 90% within 24 months using ISO 17556:2019, as well as ecotoxicity testing per OECD 208:2006 and OECD 207:1984. The standard also limits residual additive content and requires declaration of soil degradation behavior before commercial placement. Production on cast film equipment uses a slot die of 1.8 m to 2.6 m working width, die gap 0.6 mm to 0.9 mm, melt temperature 165 °C to 190 °C, and a polished chill roll at 20 °C to 28 °C. Slot draw and edge pinning are controlled to avoid neck-in beyond 5% of die width, because the filled melt exhibits limited strain hardening. Terminal product types are smooth or embossed black mulch films, layflat widths from 0.8 m to 1.4 m, and roll lengths from 200 m to 400 m, for use in tomato, pepper, and strawberry bed culture.
| Film structure | Die gap | Melt temperature | Blow-up ratio / draw | Thickness |
| Retail carrier bag | 0.9–1.2 mm | 168–182 °C | 3.0:1–3.8:1 | 18–35 µm |
| Organic caddy liner | 0.8–1.0 mm | 158–168 °C | 3.0:1–3.5:1 | 12–20 µm |
| Cast lamination | 0.5–0.8 mm | 170–190 °C | air gap 100–180 mm | 10–25 µm |
| Agricultural mulch | 0.6–0.9 mm | 165–190 °C | neck-in below 5% | 10–25 µm |
| Produce roll bag | 0.8–1.0 mm | 165–178 °C | 2.8:1–3.5:1 | 10–18 µm |
At 10 µm to 18 µm, produce roll bag film demands high clarity, controlled slip, and predictable perforation tear across high-speed bag conversion. PHACT™ CA1240PF is dry-blended at 15 wt% to 35 wt% with a PLA-rich terminal matrix, while a separate migrating slip masterbatch is added at 0.5 wt% to 1.5 wt%. The mineral phase in this gauge range functions primarily as an antiblock and gauge stabilization additive, reducing blocking at roll storage temperatures up to 40 °C without requiring excessive inorganic anti-block addition. At addition above 35 wt%, haze per ASTM D1003-13 exceeds 10%, which is above the acceptability limit for consumer produce visibility; at addition below 15 wt%, the film exhibits blocking defects after 7 days of roll storage. Food-contact compliance is assessed under EU Regulation (EU) No 10/2011 with overall migration below 10 mg/dm², and United States suitability is governed by current PLA food-contact notifications. Compostability certification for the single-use film is verified under EN 13432:2000/AC:2005 or ASTM D6400-21 depending on the municipal disposal stream. The blown film line for this gauge uses a die gap of 0.8 mm to 1.0 mm, internal bubble cooling, blow-up ratio 2.8:1 to 3.5:1, and melt temperature 165 °C to 178 °C. The bubble is collapsed through an S-wrap with nip pressure 0.8 N/mm to 1.2 N/mm and surface winding tension 0.2 N/mm to 0.4 N/mm. Terminal product types are perforated single-use produce roll bags and star-sealed bottom-seal or side-seal formats.
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PHACT™ CA1240PF is a pelletized blown/cast film compound in which a polylactic acid matrix is modified with amorphous polyhydroxyalkanoate and a calcium compound fraction. The grade designation indicates a calcium-bearing film formulation; the exact PLA:aPHA:calcium compound ratio is lot-specific and is reported on the certificate of analysis. In this material class, aPHA acts as a ductility modifier that interrupts large-area craze propagation in thin sections, while the calcium compound raises low-shear melt stiffness and modifies film surface texture. Unlike unmodified PLA film resin, PHACT™ CA1240PF is supplied as a formulated compound with dispersion aids, stabilization, and optional antiblock. Melt flow rate is characterized under ISO 1133-1:2022 at 190 °C with a 2.16 kg load; density is measured under ISO 1183-1:2019. Pellet is supplied in 25 kg foil-lined packaging and should be stored below 35 °C to avoid sintering and moisture uptake.
Before extrusion, moisture handling is critical because PLA and aPHA hydrolyze at elevated temperature when residual moisture exceeds approximately 250 ppm. Desiccant drying with a supply air dew point no higher than −40 °C and a bed temperature of 75 °C to 85 °C for 4 h to 6 h is the standard pre-extrusion protocol for this compound class. In plants where ambient relative humidity exceeds 60%, hopper loading should use dry-air conveying, and hopper openings should remain closed. Failure to dry produces hydrolysis-induced melt viscosity loss, surging at the die, gauge bands in blown film, lactide plate-out on air rings, and adhesion to cast-film chill rolls. Because the calcium compound is hygroscopic, long transfer lines should be nitrogen-purged and protected with 25 µm sintered metal filters upstream of the feed throat.
On a conventional 45 mm single-screw extruder with an L/D 28:1 barrier screw, start-up barrel settings for PLA/aPHA/CaCO₃ film compounds of this type fall between 150 °C and 190 °C, with die temperatures between 180 °C and 195 °C. Bubble stability is controlled by the interaction between aPHA shear thinning and the low-shear viscosity contribution of the calcium compound. Starting conditions for blown film include a die gap of 0.8 mm to 1.2 mm, a blow-up ratio between 2.0 and 3.5, and a frost-line height of 1.5 to 4.0 die diameters. These settings are not grade-specific fixed constants; they must be adjusted against melt pressure, frost-line temperature, and thickness variation measured under ASTM D8136. Maintaining die temperature below 200 °C is important because extended residence above that threshold accelerates aPHA degradation and promotes lactide condensation on air ring surfaces. Screen packs in the 60/80/100 mesh range reduce calcium agglomerate passage, but pressure drop across the pack should be recorded every 30 min to detect filler accumulation or gel formation.
The calcium compound fraction governs optical and surface performance. Film-grade formulations of this type typically employ surface-treated ground calcium carbonate with a median particle size D50 between 1.0 µm and 2.5 µm. A shift above this range increases wide-angle light scattering and raises haze measured under ASTM D1003, particularly in film below 30 µm. Loading levels in PLA/aPHA/CaCO₃ film compounds commonly range from 10 wt% to 25 wt%, but the exact loading for CA1240PF is lot-specific. At these loadings, compound density rises from approximately 1.24 g/cm³ for unfilled PLA to between 1.30 g/cm³ and 1.45 g/cm³, which directly affects roll weight, yield per tonne, and freight mass. Static and kinetic coefficients of friction are measured under ISO 8295; effective slip and antiblock response depend on particle shape, stearate surface treatment, and plate-out behavior during processing.
Where PHACT™ CA1240PF differs from unfilled PLA film is the combination of ductility, melt stiffness, and density. Unfilled PLA film typically exhibits tensile elongation at break below 10% under ISO 527-3:2018; aPHA-containing film can sustain substantially higher elongation, though the exact value depends on draw ratio, aPHA content, and calcium compound loading. Compared with PLA/talc compounds, the aPHA phase contributes a lower-temperature relaxation shoulder and improves resistance to fold cracking, while talc raises bending modulus without the same toughness modification. Compared with PBAT-rich biodegradable film, the compound retains a higher renewable carbon fraction under ISO 16620-2 and generally exhibits lower machine-direction tear propagation unless post-oriented. Published data for this specific CA1240PF configuration are limited; therefore, lot-specific tensile, tear, and optical values must be obtained from the certificate of analysis rather than inferred from general PLA/aPHA literature.
For cast film production below 25 µm, the die body should maintain transverse melt temperature variation within ±1.5 °C, and die lips should be flat-polished to avoid draw streaks. The calcium compound increases melt density and can reduce neck-in during melt curtain drawdown; however, the higher density can also promote draw resonance if take-off speed exceeds the compound’s melt relaxation rate. Chill-roll temperatures between 15 °C and 30 °C are typical start-up values for rapid quenching of PLA/aPHA cast film, while air knife pressure in the range of 0.15 MPa to 0.30 MPa stabilizes the curtain against edge flutter. Thickness standard deviation measured under ASTM D8136 should remain below 5% of mean thickness for monolayer structures. Gauge instability at high line speed indicates insufficient melt relaxation, excessive moisture, or calcium compound agglomerates; the corrective sequence is to verify drying, reduce filler loading if permitted by the product specification, and lower draw ratio rather than raise die temperature above 200 °C.
The rheological signature of PHACT™ CA1240PF differs from neat PLA in two ways. First, the calcium compound fraction contributes a measurable low-shear yield stress that suppresses bubble sag and improves bubble symmetry at low draw speeds. Second, aPHA broadens the shear-thinning response, which reduces motor load at high screw speeds but can also reduce melt extensional strength if the aPHA phase is overheated. Production lines should log melt pressure before and after the screen pack, melt temperature at the adapter, and die pressure every shift. A rising screen-pack differential at constant throughput indicates filler agglomeration or contamination; when differential pressure increases by more than 25% from baseline, the screen pack should be changed. Melt temperature should be measured with an immersion thermocouple at the die adapter, not inferred from barrel set points, because viscous heating can raise actual melt temperature by 3 °C to 8 °C at screw speeds above 80 rpm in 45 mm extruders.
Low-speed puncture resistance is measured under ISO 7765-1; Elmendorf tear propagation is tested under ISO 6383-2 or ASTM D1922. In PLA/aPHA film, the amorphous PHA phase reduces notch sensitivity at ambient temperature because its low glass transition, typically below −10 °C, permits local shear yielding ahead of the tear tip. However, calcium carbonate particles can act as stress concentrators if surface coating is incomplete or if agglomerates exceed 10 µm. In that case, transverse-direction tear resistance deteriorates disproportionately because the particle-matrix interface fails before the surrounding polymer can yield. Heat-seal behavior is characterized under ASTM F88; PLA/aPHA films generally form seals in the 85 °C to 120 °C range, but the calcium compound influences seal bar contact and heat transfer rather than seal interface chemistry. Seal strength reaches practical stability after the sealing bar dwell time exceeds 0.5 s to 1.0 s; shorter dwells produce variable peel separation and seal failure through interfacial delamination.
| Property | Test method | PLA/aPHA/CaCO₃ film class | Unmodified PLA film | PLA/aPHA unfilled film |
|---|---|---|---|---|
| Melt flow rate, 190 °C/2.16 kg | ISO 1133-1:2022 | 3–7 g/10 min | 4–8 g/10 min | 2–6 g/10 min |
| Density | ISO 1183-1:2019 | 1.30–1.45 g/cm³ | 1.24–1.26 g/cm³ | 1.20–1.28 g/cm³ |
| Tensile modulus, film | ISO 527-3:2018 | 2.2–3.2 GPa | 3.0–4.0 GPa | 1.8–2.8 GPa |
The table lists published typical ranges for related film-grade PLA/aPHA/CaCO₃ compounds, unmodified PLA, and unfilled PLA/aPHA blends. These ranges are not CA1240PF certificate values and are provided only to indicate the directional property differences expected when aPHA and calcium compound are combined with PLA.
In compostable flexible packaging and non-contact food packaging evaluations, PHACT™ CA1240PF is assessed under EU Regulation 10/2011 migration testing and FDA 21 CFR 176.170. Overall migration limits are simulant-dependent and cannot be assumed from resin composition alone. For industrial compostability claims, certification bodies require disintegration, biodegradation, and ecotoxicity data. The calcium compound fraction is inorganic and does not biodegrade, but it can contribute to fragmentation and must be considered in the disintegration mass balance. Heavy-metal limits are established under EN 13432; the calcium carbonate source must be screened for cadmium, mercury, lead, and chromium because mineral ore supply is the main variable in heavy-metal compliance. Any contact-sensitive application should use a separate migration study with the actual film thickness, seal geometry, and food simulant, not a generic resin statement.
Compostability evaluation for PLA/aPHA/CaCO₃ film is structured around three parameters: aerobic biodegradation, disintegration, and chemical safety. Aerobic biodegradation is measured under ISO 14855-1 as evolved carbon dioxide; the organic polymer fraction must reach the specified mineralization threshold within the test period. Disintegration is assessed under ISO 20200 or ISO 16929, where the final compost is sieved through a 2 mm screen. Calcium carbonate can alter the particle-size distribution of the remaining fragments, so sieve retention should be reported separately from organic conversion. Chemical safety includes the heavy-metal limits of EN 13432, ecotoxicity testing, and fluorine content where applicable. Because the calcium compound is inert in composting, the measured mineralization percentage must be normalized to the organic polymer content; this normalization is required to avoid false pass or fail interpretation.
| Compliance parameter | Standard designation | Measurement basis | Relevance to PLA/aPHA/CaCO₃ film |
|---|---|---|---|
| Aerobic biodegradation | ISO 14855-1 | CO₂ evolution; organic carbon conversion | PLA and aPHA organic phases mineralize; CaCO₃ does not |
| Disintegration | ISO 20200/ISO 16929 | Fraction passing 2 mm sieve after 12 weeks | Mineral fraction affects fragment size distribution |
| Heavy metals and chemical safety | EN 13432 | mg/kg dry substance | Calcium carbonate ore purity controls cadmium, lead, chromium, mercury |
| Renewable carbon content | ISO 16620-2 | Biobased carbon fraction of total organic carbon | Calcium carbonate is inorganic; renewable carbon is determined on the polymer matrix |
For CA1240PF, the compliance file should include a lot-specific heavy-metal certificate for the calcium compound fraction, a biodegradation report normalized to organic content, and a disintegration report at the intended maximum film thickness. Without these three documents, a blanket compostability claim is not technically defensible under EN 13432 or ASTM D6400.
On production-scale blown film lines, two recurring process conflicts dominate. First, raising calcium compound loading above the specified lot limit improves bubble stiffness but narrows the processing window by increasing screen-pack pressure and reducing tear resistance. Second, moisture uptake in high-humidity plants reduces melt viscosity and destabilizes the frost line, which operators may misdiagnose as a barrel temperature fault. The correct diagnostic sequence is to measure pellet moisture, verify dryer dew point, and inspect screen-pack differential before changing temperature profile. When these controls are maintained, PHACT™ CA1240PF can be converted on conventional PLA-capable blown and cast film equipment with the same general downstream handling used for filled biodegradable films.
In agricultural film and non-contact packaging trials, the compound’s calcium fraction reduces blocking on roll storage compared with unfilled PLA/aPHA film, but it raises film density and alters the mass per unit area at constant thickness. If a converter replaces unfilled PLA with CA1240PF, the roll length calculation must be corrected using density from ISO 1183-1:2019; a thickness-only comparison under ASTM D8136 will underestimate yield loss from density increase. Biaxial orientation is possible only within the draw ratio limits inherent to PLA-based compounds; the presence of calcium particles can initiate cavitation at high draw ratios, producing opaque microvoided film. This behavior may be beneficial for breathable film segments but must be intentionally designed, not discovered during commercial scaling.
No direct substitution should be made from another calcium-filled PLA grade or from unfilled PLA/aPHA without a trial on the target line because die geometry, screw design, and downstream gauge control interact with filler dispersion. The product is best evaluated using a designed trial that records melt pressure, melt temperature, film thickness profile, haze, tensile properties, tear resistance, and seal strength under the standards cited above. When those measurements are collected, the operational boundaries of CA1240PF become visible as a combination of density, draw stability, filler dispersion quality, and ductility that differs from both unfilled PLA and conventional PLA/talc film compounds.
