BCML organises webinar on PLA bottles for plastic-free drinking

On 18 August, Balrampur Chini Mills organised a panel discussion, 'Thirst for Change: PLA Bottles for Plastic-Free Drinking', featuring Dr SK Nayak, chief advisor to BCML - PLA business; Aliasgar Vora, founder of Sunny Enterprises, director-Green Bioblend; and Pradeep Kokkat, founder and managing director, Greenbio Products. Stefan Barot, president-chemical division, BCML, delivered the welcome address and the discussion was moderated by Shweta Suryawanshi, general manager - business development, BCML. 

The webinar on PLA bottles brought together experts from academia, research, and industry to critically examine whether polylactic acid (PLA) can emerge as a genuine alternative to conventional plastics in India’s packaging sector.

At the outset, the speakers highlighted the promise of PLA. Suryawanshi explained how PLA is derived from renewable feedstock such as corn or sugarcane, making it a compostable material under the right conditions. Its origin in biobased resources aligns with the global and national momentum towards sustainable alternatives. Ali Asgar added that PLA can rival PET in both clarity and strength, giving it an edge when it comes to consumer acceptance, since the appearance and performance of the bottles remain familiar.

Policy support was another positive factor discussed during the session. Dr Nayak pointed out that India’s regulatory push towards sustainable materials and the phasing out of single-use plastics is creating fertile ground for biopolymers such as PLA. Adding to this, Pradeep Kokkatt described Greenbio’s initiative of producing 100% compostable PLA preforms and caps. He noted that the company has deliberately targeted premium segments to begin with, where consumers are more likely to pay for sustainable packaging and are increasingly eco-conscious.

During the session, the panel also explored PLA’s characteristics in greater technical detail, especially its role in blown films and packaging applications. It was noted that PLA offers high clarity and gloss, giving it a strong visual appeal comparable to PET. Its stiffness and strength make it suitable for rigid packaging, while its inherent compostability under industrial conditions provides an environmental edge. However, the limitations were also underlined: PLA has a lower heat resistance than conventional plastics, which restricts its use in hot-fill or high-temperature applications. The speakers observed that blown film processing with PLA can be challenging due to its brittleness and slower crystallisation, often requiring additives or blending with other biopolymers to achieve flexibility and sealability. Moisture sensitivity was another drawback, as it affects both processing and end-use performance. While PLA demonstrates strong potential in niche and premium segments, the panel agreed that large-scale substitution of mainstream plastics in films and bottles remains difficult without significant improvements in its mechanical and thermal properties.

Kokkat's Greenbio Products, a Kerala-based startup has emerged as a compelling real-world exemplar of PLA’s potential in action. The company offers a diverse product line that includes 100% compostable bottles, caps, cling films, grocery and carry bags, and other biodegradable packaging solutions. According to their website, they are firmly aligned with global biodegradability standards such as ASTM D6400, EN 13432, ISO 17088, and approved by India’s Central Pollution Control Board. Kokkatt also shared how Greenbio's PLA water bottles recievced positive feedback from eco-conscious consumers; however the challenge lies in scaling adoption across the mainstream market. High costs, longer processing cycles, and lack of widespread composting or dedicated PLA recycling infrastructure have limited uptake.

Beyond bottles, the speakers also pointed to emerging uses in thermoformed trays, cutlery, and packaging films, where its compostability and renewable origin offer an advantage. Still, the consensus was that in its current form, PLA is being used in select applications where brand differentiation and sustainability credentials outweigh cost and performance limitations.

The debate also highlighted the key challenges with PLA. Several speakers raised the critical issue of perception: PLA looks like plastic and behaves like plastic. Without widespread consumer education and awareness, there is a risk that people will treat it exactly like conventional plastics, leading to contamination in existing waste streams. Processing was another point of contention. Asgar admitted that PLA requires tighter production controls and longer cycle times, around 25 to 30% more than PET, which increases costs and slows down output. While additives and annealing can mitigate these issues, scaling up remains a concern. Kokkatt reinforced the point by sharing that people’s first reaction to PLA bottles is often scepticism. The question he hears repeatedly is: “If it looks like plastic, why pay more?” According to him, only a combination of awareness campaigns and government-backed pilot projects will change consumer behaviour.

The discussion also highlighted the lack of infrastructure as a major roadblock to circular economy. While India has been proactive in announcing bans and regulatory frameworks, the absence of industrial composting facilities and effective segregation systems threatens to undermine PLA’s sustainable promise. In its current state, PLA risks being dumped into the same waste streams as PET, where it cannot deliver its environmental benefits. The speakers agreed that the gap between policy ambition and ground reality must be addressed if PLA is to succeed.

In conclusion, the panel agreed that PLA cannot be considered a silver bullet. Instead, it should be seen as a bridge between the petroleum-based plastics of today and the more sustainable materials of tomorrow.