PLA 101: Everything You Need To Know About The Original Bioplastic

Jun. 05, 2025

PLA 101: Everything You Need To Know About The Original Bioplastic

New and improved bioplastics are hitting the manufacturing world, seemingly, every week, but what about those that truly started the trend? Made from renewable sources and fully biodegradable, the original bioplastics offered an optimistic look at how packaging production could evolve but are we being too quick to forget about the likes of PLA, in the face of even more promising alternatives such as PHA?

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What is PLA?

PLA is a natural polyester commonly made from cornstarch or sugarcane. When ready to use, it has properties not dissimilar to polypropylene, polyethylene, or polystyrene.

First discovered all the way back in the s, by Wallace Corothers, the inventor of Nylon, PLA was never fully realised as a commercial material but by , it was the second most valuable bioplastic in the packaging market, according to consumption figures.

PLA is also known by the following monikers:

Polylactic Acid
Polylactide

How is PLA made?

As with most bioplastics, a controlled environment that encourages fertilisation is needed for PLA synthesis to occur, but as opposed to needing bacteria to grow granules that can be harvested, as with PHA, carbohydrates are the most important element here.

Typically, cornstarch, sugarcane and tapioca starches are used, depending on manufacturer location. Starches are separated from the initial material, before being mixed with acid or enzymes and finally, heat, which allows dextrose to be isolated and this is where the magic happens. Fermentation of the dextrose leads to lactic acid production and that’s the basic building block of commercially viable PLA. From here, polymerisation occurs so that volume can be multiplied and a finished bioplastic produced quickly and cost-effectively.

The following diagram breaks the process down into a simple visual:

Notably, PLA can be made using already in-situ manufacturing equipment originally designed to create petrochemical plastics, meaning that the price to switch over to a more responsible alternative is negligible and not a prohibitive reason to stall.

Who is using and making PLA?

PLA is being used throughout multiple high-value industries, demonstrating a clear demand for bioplastic evolution. Thanks to the ease with which it can be made, using said existing equipment, manufacturers can offer an environmentally beneficial alternative to traditional plastics, which offers clients an opportunity to update their branding with greener marketing.

Current industry users include:

Food packaging: As a food packaging application, PLA is cost-effective and Generally Recognised as Safe (GRAS), though without additives it can be limited in the number of products it can be used to make. There is a risk of lactic acid leaching, when PLA comes into contact with certain liquids, though tests have indicated that levels are not harmful to humans. It has been used to produce cups, tea bags, bottled and films.

Medical: Similarly to PHA, PLA is bio compatible and can be used within the human body in the form of medical aids and support systems. The risk of infection is minimal and the range of applications is vast, from screws to plates and even tissue engineering. PLA dissolves in the body without toxic repercussions and is a lighter alternative to traditional metal.

Construction: A slightly tenuous one here. PLA can be used for very specific applications, such as insulation, but because it degrades fully, use is very limited right now. No structural uses are yet approved.

Textiles: As fabric composition continues to dominate the evolution of the fashion industry, PLA has risen through the ranks to become a viable alternative to synthetic polyesters. It is particularly useful for sportswear that requires high levels of breathability coupled with a lightweight feel, but its most industry-changing property is its recyclable nature. It has been heralded as a key player in the move towards a circular fashion economy.

Some of the largest manufacturers of PLA are:

NatureWorks

A joint-venture between Cargill (US) and PTT (Thailand), NatureWorks has some very exciting ideas being tested. Already using plants in an earth-positive way, the company transforms greenhouse gases into sugars that can, eventually, be polymerised. This technology is being improved all the time and there is scope to negate the use of plants as well. Using abundant feedstocks, NatureWorks has, since , looked to keep improving the potential of PLA and today is highly respected for its flagship end product, Ingeo. It has a presence in more than 10 countries, supplying businesses in the US, Europe, Japan and Asia Pacific.

WeforYou

One of the leading manufacturers of now only reusable but also sustainable bags, WeforYou produces biopolymer shoppers in its facilities in China and supplies them throughout the world. The company speaks of a holistic approach from start to finish, which sees raw bio materials being transformed into a lasting and recyclable product.

Total-Corbion

Another joint venture, this time between Total (France) and Corbion (NL), Total-Corbion demonstrates an important shift in traditional production methodologies for existing petrochemical companies. Luminy® is the key offering here and comes in two formats, standard and high-heat applications. Created for a vast array of uses, it has already been utilised as food serviceware, food packaging and within the 3D-printing sector. The production facility is located in Thailand, with customers supplied globally.

Why is it better than plastic?

There are many ways in which PLA is an environmentally superior alternative to standard plastics but the main benefits are reduced carbon footprints during production, cost-effectiveness of the switch to manufacture and of course, the recyclable nature at EOL. This being said, PLA isn’t without its critics or downsides.

Arguments for and against PLA

There’s no denying that in comparison to regular plastics that have no option but to be sent to landfill at EOL, PLA is an attractive and environmentally aware response to a growing need. It’s important to look at the full picture though, including criticisms, limitations and potential issues that stem from PLA use.

Pros:

PLA is made from entirely renewable raw materials and is biodegradable, so it will return to natural materials as it decomposes. Optimal conditions will significantly speed up the process, but even when slower, the degrading will be complete. It is also listed as being compostable.
It can be used in regular petrochemical plastic manufacturing plants, meaning no initial expenditure is needed in terms of infrastructure to work with it.
PLA is a thermoplastic, so it can be reshaped and moulded a number of times, without affecting its mechanical structure.
It can be made worldwide, using a variety of carbohydrate sources that are grown locally, allowing for further carbon footprint reductions.

Cons:

It is still more expensive than petrochemical plastics, making it prohibitive to some.
Critics have been quick to decry the use of food crops as raw materials, though this was more in 1st gen PLA and non-edible food crops have since been used.
Though it can be composted, it does not degrade into matter that offers any nutrients or benefits to the earth. The end material is therefore not ‘compost’. It will make soil more acidic too.
It is recyclable, both chemically and mechanically, but this requires speciliased facilities.
The low melting point also makes PLA unsuitable for certain applications that will necessarily involve heat.
It is not a structurally protective plastic alternative and offers oxygen and moisture permeability, meaning that only short-term food storage is advised.

The use of PLA in packaging

Taking hot food and beverages out of the equation, PLA is a great option for packaging materials, with the Food and Drug Administration (FDA) recognising it as suitable and safe. Applications are varied, ranging from plastic water bottles and cups to flexible films, extruded containers and moulded packages, such as yoghurt pots. Packaging should be used as a short-term food storage option, making it ideal for fresh and short shelf-life items.

Additives can be included to open up a wider array of packaging solutions, including those for high-heat applications, though this raises questions as to the environmental credentials of the finished product and can impact EOL responsibilities for manufacturers.

Did PLA start the bioplastics trend?

In short, yes. PLA should not be overlooked in terms of the impact it had on highlighting alternatives to traditional petrochemical plastics and though it has its critics and some would say it has been superseded by the likes of PHA, it is continuing to evolve. If its shortcomings linked to heat and easy recyclability can be improved upon, PLA could once again be hailed as a future solution that everybody needs to get onboard with. So perhaps the question should be: will PLA be the ultimate bioplastic that not only started but also ends the discussion about viable environmental packaging solutions?

Is PLA Food Safe? Understanding Its Toxicity and Use in 3D Printing

PLA is a safe and environmentally friendly alternative to common packaging materials.

Is PLA food safe? In short, PLA is a biodegradable and bioactive thermoplastic derived from renewable resources (e.g., corn starch or sugar cane). It's generally considered safe and used for packaging food.

However, we suggest using PLA products that specifically mention compliance with relevant food safety standards to ensure they are suitable for your particular food handling needs.

Polylactic acid (PLA) has recently emerged as a common material in the food industry. That’s because it offers a sustainable and innovative alternative to traditional plastics.

From packaging materials to disposable tableware, PLA's applications in the food sector are expanding. This is driven by a growing emphasis on environmental responsibility and the pursuit of more sustainable practices.

Does it contain any toxic particles or harmful substances? What about toxic chemicals? Read along as we explore these important questions in detail.

What is PLA?

PLA is a biodegradable and bioactive thermoplastic made from corn starch or sugar cane. It is used as a sustainable alternative to traditional petroleum-based plastics for packaging materials, disposable tableware, and other food-related products.

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PLA’s material properties are enough to produce a plastic-like material that can act as packaging for foods at ambient temperature. At the same time, it is known for its eco-friendliness because it can break down into harmless byproducts in composting environments or does not release any toxic substances during degradation.

As a result, it’s gaining more popularity on an industrial scale because of the drive to reduce single-use plastic waste by using compostable materials for food products.

Understanding the PLA filament

You might come across the term “PLA filament” and it’s important to distinguish it from PLA. PLA filament or plastic filament refers to a specific 3D printing material made from PLA using a 3D printer. This means that the filament is derived from PLA and combined with additional additives.

PLA is the general term for the polymer, while PLA filament is a specific form of PLA designed for use in 3D printing technologies.

While PLA filament is generally considered safe for food contact, the final safety of 3D-printed items depends on factors such as the quality of the filament, the print materials, execution of food-safe 3D printing, and any post-processing treatments (such as chemical smoothing) applied.

If the intention is to use 3D-printed items for direct food contact, it's advisable to use PLA filament labeled as food-safe and follow any recommended cleaning and maintenance guidelines.

That’s because not all 3D printing filaments pass safe food grading. Some may cause food safety concerns and develop dangerous chemicals or the growth of bacteria when they come in direct contact with food.

What is PLA made of?

PLA is made mainly of cornstarch or sugar cane, a common food ingredient. The production process involves the following steps:

Fermentation. The raw material is subjected to a fermentation process using microorganisms. This process converts starch into lactic acid.
Chemical processing. The lactic acid is then chemically processed to create a monomer called lactide.
Polymerization. Lactide monomers undergo polymerization, a process where they link together to form long chains, forming a PLA polymer. The polymer is then used for making 3D prints.

Food businesses using PLA must ensure the raw ingredients used to produce PLA are all food-grade materials that will not lead to foodborne illnesses.

Is PLA food-safe?

PLA is generally considered safe for food contact. This property makes it popular for food packaging, disposable tableware, and custom 3D-printed items used in food-related contexts.

Despite this, ensuring the safety of PLA in food products requires attention to certifications, intended use, and considerations specific to the 3D printing process.

Here are four important considerations to keep in mind:

Non-toxic composition: PLA is derived from organic compounds like corn starch and is considered non-toxic. It has no health concerns, which makes it a popular choice for food-related applications.
Biodegradability: PLA is biodegradable and made of biocompatible materials, adding to its environmentally friendly profile. However, its biodegradability depends on specific conditions, such as those found in industrial composting facilities. This means that degrading PLA may not be easy for small businesses.
Certification: If you intend to use PLA for food products, especially in manufacturing or packaging, it's crucial to ensure that the product you use is certified as food-safe. You want to look for products that comply with relevantfood safety regulations and standards
Temperature sensitivity: PLA has a lower heat resistance compared to other plastics (like plastic bottles). While it is suitable for pre-packaged foods, it may not be ideal for hot liquids or foods.

Importantly, PLA is not exempt fromfood contamination. Bacteria buildup may still occur if it’s not handled properly. This means handling PLA requires strict control of temperature and sanitation.

Is PLA filament food safe?

In a Reddit thread on PLA food safety, people agree that it is food-safe. Although in the context of 3D printing, some caution against using food-grade filament with wet unsealed food because the plastic is porous and its texture is often rough. This increases the likelihood of 3D-printed products collecting food and dirt, resulting in bacterial contamination.

You can use FoodDocs' smart Food Safety Management System to automatically generate monitoring tasks for recording temperature and sanitation practices. You want to record product temperatures before packaging to ensure they are not high enough to create a ground for bacteria.

Is PLA toxic?

PLA is generally considered non-toxic under normal use conditions. Here are a few key points about its safety:

Biocompatibility: PLA is widely used in medical applications, such as sutures and implants, which indicates its high level of biocompatibility and safety for human contact.
Non-toxicity: PLA is made from renewable resources like corn starch or sugarcane, which naturally leads to a lower risk of toxicity compared to some petroleum-based plastics. It does not contain toxic substances such as bisphenol A (BPA) or phthalates, which are often concerns with other plastics.
Degradation products: When PLA degrades, it breaks down into lactic acid, a naturally occurring substance in the human body, further supporting its non-toxic profile.
Use and disposal: Under normal environmental conditions and use, PLA is safe and poses minimal risk of toxicity. However, if incinerated at high temperatures, it could potentially release any residual monomers or additives used in its manufacture, which could be harmful if inhaled in significant quantities.

Overall, PLA is a safer alternative in many uses, especially where direct contact with the human body or food products is concerned. However, it's always good to consider the entire lifecycle and conditions of use of any material to fully understand its safety implications.

How is PLA used in the food industry?

PLA has a wide range of applications in the food industry. Here are five common uses you should know about:

Packaging materials. PLA is used to make biodegradable and classic food containers for products. This includes containers, trays, cups, and films. These packaging materials can be used for various products, from fresh produce to pre-packaged meals like sandwiches.
Biodegradable cutlery. PLA-based cutlery — such as knives, forks, spoons, and other ordinary kitchen utensils — provides a more environmentally friendly alternative to traditional plastic cutlery. These ideal materials can be composted under the right conditions.
Molds and cutters. 3D-printed molds and cookie cutters made from PLA filament can be used in the production of chocolates, cookies, and other confections. These utensils are traditionally made using stainless steel.
Food service ware. PLA is used to produce food service items like trays, clamshells, and food containers. These items are designed for one-time use and can be disposed of in composting facilities.
Lining for paper cups. PLA is also used as a lining material for paper cups, providing a more eco-friendly alternative to traditional plastic-lined cups.

Keep in mind that while PLA is considered more environmentally friendly than traditional plastics, its biodegradability depends on the presence of industrial composting facilities.

How can you manage safe PLA packaging with FoodDocs?

The effectiveness of PLA as food packaging can be achieved only if favorable conditions for the material are consistently maintained. This is why food handlers must ensure that PLA packaging materials are stored in the right conditions and used only for appropriate food products. FoodDocs'AI-powered Food Safety Management System can automatically generate relevant food safety monitoring tasks to help you ensure this. It offers:

Temperature log to ensure appropriate PLA packaging
Cleaning and sanitation checklist to help ensure the PLA packaging is free from contamination
Real-time dashboard to help identify areas that need more attention

Temperature log to ensure appropriate PLA packaging

Food inside PLA packaging must be at a temperature lower than 60°C (140°F). Steel hot food may cause shrinking or warping of the packaging material.

You can use FoodDocs' automatically generated monitoring tasks for logging the temperature of food before wrapping it in PLA packaging. This monitoring task will ensure that the integrity of the packaging material is retained even after shipping the packed product.

You can also further customize the temperature log by inputting the target internal temperature before packaging. Our system will then recognize this standard and suggest corrective actions in case of non-compliance.

Cleaning and sanitation checklist to ensure PLA packaging is free from contamination

PLA must be kept in a clean space to prevent it from collectingbiological hazards and causing food poisoning. This contamination is likely when you have an untidy kitchen and working area.

To prevent this, ensure that all food handlers and facilities in your business follow critical cleaning tasks using our automatically generated Cleaning and Sanitation checklist.

This checklist contains the essential tasks to protect PLA packaging and your products from anyfood safety hazards. You can also customize it by adding specific handling tasks for PLA packaging.

Real-time dashboard to identify areas that need more attention

Ensure your team and operations comply with food safety standards with a quick overview using our real-time dashboard. With the help of this feature, you can easily identify key areas that require more attention. You can quickly detect non-compliant food safety tasks and come up with immediate solutions to minimize further problems.

Our research shows that this saves at least 20% of the time it takes you to supervise your team and allows you to focus on more meaningful areas of your business.

Remember, for PLA food packaging to work well, it's crucial to store it properly and maintain an appropriate food contact time. Food handlers can make this easier by relying on FoodDocs'AI-powered system, which automates monitoring tasks and helps maintain the quality of both the PLA packaging and the food inside.

Book afree demo now to understand how our software can help you.

Contact us to discuss your requirements of Pla Shrink Film. Our experienced sales team can help you identify the options that best suit your needs.

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