Optimization of manufacturing processes for PS-paper powder compounds in sustainable foodservice plates

The increasing demand for sustainable foodservice packaging has prompted the exploration of alternative materials that balance performance and environmental impact. This study investigates the potential of incorporating paper powder into polystyrene (PS) to develop eco-friendly foodservice plates. PS was compounded with paper powder at varying weight fractions (10%, 15%, and 20%), alongside compatibilizers and processing aids to improve dispersion and material properties. The compounding process was optimized using a twin-screw extruder, followed by film production via minicast extrusion. The processing temperatures dropped by 18% compared to pure PS, suggesting meaningful energy savings. Various characterization tests, including density, melt flow rate (MFR), tensile properties, impact strength, tear strength, and heat deflection temperature (HDT), were performed to evaluate the compounds’ mechanical performance and processability. The results showed that the addition of paper powder reduced the density (by 3.8%) and MFR of the PS compounds, indicating potential environmental benefits, such as reduced material usage and transportation costs. While the tensile strength and impact resistance decreased with increasing paper content, tear strength improved significantly, making the compounds suitable for foodservice applications. The thermal stability of the compounds remained comparable to pure PS, suggesting that paper powder incorporation does not negatively impact the material’s performance under moderate temperatures. Additionally, the incorporation of paper powder led to a darker color in the films, with processing temperatures adjusted to mitigate excessive darkening. This study demonstrates that PS-paper powder compounds offer a promising alternative for sustainable foodservice packaging, combining reduced environmental impact with adequate mechanical properties for practical use in disposable tableware.