During 2007 our company introduced three different packages made from polylactic acid (PLA). These compostable structures presented tough challenges. PLA films tear easily. This creates problems both for producers and users. Improper control of tension while printing causes the film to rip during production. And users cannot punch holes in the film for respiration because the holes weaken the film so much tears propagate easily. Also PLA does not allow oxygen in—it is almost a complete barrier—which renders it unusable for fresh produce applications.

We solved both problems. Our printing presses have the modern tension controls required to run PLA. But our quality control department and team leaders also coached our operators through the process of watching the film closely enough to make sure sudden changes in tension, usually caused by film variation, didn’t cause breaks. We solved the breathability issue by using our laser microperforator to make 110 micron holes in the film, big enough to allow air in, small enough not to tear.

Today we provide PLA film to customers packaging spinach, spring mix and green onions.