DESC:TITLE

Bio-compostable multi layered composite and methods of manufacturing the same.

FIELD OF INVENTION

The present invention relates to multi-layered composite, more particularly to bio-compostable/degradable multi-layered composite that shows better mechanical properties, is biodegradable or bio-compostable in nature and methods of manufacturing the same.

BACKGROUND OF THE INVENTION

Generally combining at least two different materials makes composite. The aim of using various materials together is to increase durability, increase elasticity and to combine the materials to arrive at unique properties; some of the combinations used to manufacture the composite are paper-polyethylene composite, plastic-paper-aluminum composite, paper-aluminum composite, plastic-aluminum composite and cardboard-polyethylene composite. The existing paper - polyethylene composite and the likes are generally used in paper cups, etc. While one of the elements of the composite may be bio-degradable, but by combining another non-degradable material(s) the total composition results in formation of residual waste thereby making it non degradable. This type of composite mentioned above are virtually all non-biodegradable and non compostable in nature.

Another known type of composite used are flexible material composites, known in market as “Flex”, which are also used widely in the market. These are virtually all non-biodegradable, and are difficult to recycle or reuse due to being complex composites having varying levels of contamination. Flex being non-biodegradable, does not compost/degrade for decades, traditionally made of PVC (Polyvinyl Chloride) and if and when burnt emits toxic fumes which have serious impact on the environment. For example, it has been seen that large number of banners and hoarding that are made from flexible materials (Flex), have multiple application due to which their usage increase and simultaneously does their non-biodegradability in nature. Therefore, it is necessary to curb the usage of such environmentally hazardous materials such as flex or flex like material with other non-degradable alternatives.

Many different materials are used for manufacturing composite that includes metals, glass, wood, paper or pulp, plastics or combinations of more than one material as composites. Among other materials, a wide range of oil-based polymers is currently used in packaging applications. Recently, significant progress has been made in the development of biodegradable packaging material, largely from renewable natural resources, to produce biodegradable materials with similar functionality to that of oil-based polymers.

WO2009106500A1, discloses a multi-layered composite materials which comprise the following components such as a plastic or metal foil, optionally at least one connecting layer and a polyurethane layer having capillaries that extend through the entire thickness of the polyurethane layer. It is an object of WO2009106500A1, to process foils such as metal foils or plastics foils such that they have an appealing visual exterior and pleasant haptic and are impervious to fingerprints, sweat stains and moisture.

Further, CN101821096B discloses high barrier multilayer films incorporating a biodegradable polymer layer. More particularly, biodegradable insulation facing materials and insulation articles incorporating a biodegradable polymer layer. The structures have excellent barrier properties and superior mechanical strength. It is the object of CN101821096B, to process environment friendly multilayer film structures having good process ability and a high barrier to gas and moisture transmission that are useful as insulation facings.

However, the degradation of the known multi-layered composite available in the prior art is such, wherein biodegradable substrate of a specific percentage is coated with non-biodegradable material of a specific percentage. Once the biodegradable substrate is coated with non-biodegradable material, said non-biodegradable material gets absorbed on the biodegradable substrate, such that the molecules of the non-biodegradable material binds to the cyclic chain of the biodegradable substrate. This chemical interaction of the biodegradable substrate with the non-biodegradable material, results in formation of non bio degradable residue. During this process non-biodegradable material gets absorbed or cross-linked with the bio-degradable fibers/substrates/materials, thus making the multi-layered material non-biodegradable/non-compostable in nature.In the end, the composite material that needs to be processed will not be discarded properly, thereby harming the environment. Usually these kind of composite materials are also not recyclable due to variants in molecular values.

One of the main challenges currently faced by the society is the lack of composite materials that rapidly and completely degrades/decompose under natural environmental conditions without leaving any residue, beyond permissible norms as per local standards and yet retain their properties such as tensile strength, heat seal/WVTR/ specific properties for a sufficient duration when used as consumer products.

Therefore in order to overcome or at least mitigates the disadvantages of existing composite, it is the prime object of the present invention to provide a bio compostable sustainable multi-layered composite that shows higher mechanical properties readily compostable in nature leaving no residual waste,, heat sealable, water impermeable, oil and grease resistant composite materials in sheet/web form for further conversion. The invention also further, describes method of manufacturing the same.

OBJECT OF THE INVENTION

The primary object of the present invention is to provide a bio compostable sustainable multi-layered composite comprising of a biodegradable substrate layer and a bio compostable material, wherein said bio compostable material uniformly adheres to at least one side of the said substrate with or without using any bio degradable or bio compostable adhesive.

Another objective of the present invention is to provide a bio compostable multi-layered composite, which is compostable in nature, as per known ISO standards.

Another objective of the present invention is to provide a bio degradable/bio compostable multilayered composite, suitable for packaging, having similar or better mechanical properties compared to presently available non degradable polymeric composites.

Another objective of the present invention is to provide a bio degradable/bio compostable multilayered composite suitable for printing, having similar or better print receptive properties compared to presently available polymeric non degradable composites.

Yet another objective of the present invention is to decrease or eliminate the formation of non-biodegradable residue.

Yet another objective of the present invention is to, optionally, enhance the quality of the soil by subjecting the bio compostable multi-layered composite to a compostable system.

Yet another objective of the present invention is to provide methods of manufacturing bio compostable multi-layered composite comprising of a biodegradable substrate layer and a bio compostable material, wherein said bio compostable material uniformly adheres to at least one side of the said substrate with or without using any bio compostable adhesive.

Yet another objective of the present invention is to make the a bio degradable/bio compostable multilayered composite that find application in various fields such as printing, including Digital Printing, sealing, packaging, etc.

Yet another objective of the present invention is to make the a bio degradable/bio compostable multilayered composite more environment friendly and cost effective.

Yet another objective of the present invention, is to provide experimental analysis, which shows comparative results between non bio degradable compostable multilayered composite and bio compostable multilayered composite.

However the foregoing objectives to be achieved will be clear from the following description. In this context it is clarified that the description provided is non-limiting and is only by way of explanation.

SUMMARY OF THE INVENTION

The primary aspect of the present invention is to provides a bio degradable/bio compostable multilayered composite comprising of a biodegradable substrate layer and a bio compostable material that uniformly adhered to at least one side of the said substrate with or without using any bio compostable adhesive, wherein said bio compostable material when degrades/decomposes acts as a compost without leaving any residue or can be incorporated in a compost system to act as a manure or to increase the fertility of the soil, thereby enhancing the quality of soil.

Further aspect of the present invention is to make the multilayered composite more environment friendly, to increase the tensile strength and to make the multilayered composite more cost effective.

According to a second aspect, the present invention provides methods of manufacturing bio compostable multi-layered composite by the methods such as (i) Blow film extrusion process; (ii) Cast film extrusion process;(iii) T-die extrusion coating process;(iv) Calendering coating process, (v) laminating process and subsequent coating.

BRIEF DESCRIPTION OF THE INVENTION

Fig. 1. Is a diagrammatic representation illustrating the known multi-layered composite available in the priorart.

Fig. 2. Is a diagrammatic representation illustrating the non-bio degradability/non-degradability of the known multi-layered composite available in the prior art.

Fig. 3. Is a diagrammatic representation illustrating the bio compostable multi-layered composite of the present invention.

Fig. 4. Is a diagrammatic representation illustrating the degradation of bio compostable multi-layered composite, when said biodegradable substrate is coated with biocompostablematerial disclosed in the present invention.

Fig. 5. Is a schematic flow chart for a direct method of manufacturing bio compostable multi-layered composite by casting melted bio compostable polymer through T-die extrusion coating process.

Fig. 6. Is a schematic flow chart for a direct method of manufacturing bio compostable multi-layered composite by casting melted bio compostable polymer through cast film extrusion process.

Fig. 7. Is a schematic flow chart for a direct method of manufacturing bio compostable multi-layered composite by casting melted bio compostable material/polymer through calendaring coating process.

Fig. 8. Is a schematic flow chart for an indirect method of manufacturing bio compostable multi-layered composite by casting/laminatingbio compostable material/polymer through blow film extrusion process.

DETAILED DESCRIPTION OF THE INVENTION

Having described the main features of the invention above, a more detailed and non-limiting description of a preferred embodiment will be given in the following paragraphs with reference to the accompanying drawings.

Biodegradable refers to the ability of materials to break down and return to nature. In order for packaging products or materials to qualify as biodegradable, they must completely break down and decompose into natural elements within a short time after disposal – typically a year or less. The ability to biodegrade within landfills helps to reduce the buildup of waste, contributing to a safer, cleaner and healthier environment. Materials that are biodegradable include corrugated cardboard and even some plastics. Most biodegradable plastics, however, are not biodegradable meaning they cannot break down easily after disposal and can remain on the planet as waste for decades, because of the presence of material such as petro-plastics.

Though, bio compostable materials are similar to biodegradable materials, as they are both intended to return to the soil safely. However, bio compostable materials go one step further by providing the soil with nutrients once the material has completely broken down. These materials are added to compost piles, which are designated sites with specific conditions dependent on relative humidity ( %RH), sunlight and other factors. While biodegradable materials are designed to break down within landfills, bio compostable materials readily degrade in the soil in presence of micro-organism, thereby enhancing the quality of the soil, thereby leaving no residue.

According to first aspect, the present invention discloses a bio compostable multi-layered composite comprising of a biodegradable substrate layer and a bio compostablematerial, wherein said bio compostable material uniformly adheres to at least one side of the said substrate with or without using any bio degradable or bio compostable adhesive, wherein said bio compostable material when degrades acts as a compost or can be incorporated in a compost system to act as a manure or to increase the fertility of the soil, thereby enhancing the quality of soil.

Further the present invention also focuses to make the multilayered composite more environment friendly, to increase the tensile strength and to make the multilayered composite more cost effective.

The biodegradable substrate layer is preferably formed of natural biodegradable materials like bio-degradable fibers, fabric, pulps like cotton, jute, hemp, bagasse, wood pulp and paper making materials. Alternatively, the biodegradable substrate layer may be formed of naturally corrosive and subsequently bio-degradable metallic foils like aluminum foil, brass foil, copper foil, tin foil, steel foil and zinc foil.

The bio compostable material may be soluble in water, i.e. a water soluble film (WSF) or non soluble in water or partially non solublethat swell under moisture and are bio degradable in nature. The WSF may be cold water soluble (CWSF), warm water soluble (WWSF), or hot water soluble( HWSF) or Non soluble hot water soluble film (NSHWSF). Further the WSF may be modified or hybrid in nature.

These material may be made of raw materials selected from acrylic acid polymers, acrylic ester polymers, acrylic acid copolymers, acrylic ester copolymers, copolymers of acrylic acids and esters, crosslinked polyvinyl alcohols, crosslinked cellulose derivatives, ethyl cellulose, nitrocellulose, cellulose butyrate, cellulose acetate butyrate, ethylene vinyl alcohol, ethylene vinyl acetate, polyvinyl acetate, polyvinylidene chloride, natural and synthetic waxes, polyurethanes and modified polyvinyl alcohols.

The bio compostable material may be made of raw materials selected from Polybutyleneadipate terephthalate (PBAT), Polyhydroxyalkanoates (PHAs),poly-3-hydroxybutyrate (PHB), polyhydroxyvalerate(PHV), polyhydroxyhexanoate(PHH), Polylactic acid (PLA), Polybutylene succinate (PBS), polycaprolactone (PCL), cellulose acetate, nitrocellulose, Polyanhydrides, Polyvinyl alcohol, Polysaccharides such as starch-based bioplastics, Proteins such asGluteneither alone or combinations thereof or any other raw material that fall under EN13432, ISO 17088:2008. EN13432 is an abbreviation used for plastic products that provide proof of their compost-ability by successfully meeting the environmental conditions.

The bio compostablematerial is alternatively a water soluble, non-soluble or partially non soluble, non hydrophilicbiodegradable/bio compostable (NSNHFD)film, (HWSF) film. A non hydrophilic film may be made out of non-hydrophilic materials, wherein at least one side may be cast with a water soluble film material and dried, to make the coated/cast side hydrophilic, to enable lamination with a biodegradable substrate with the aid of water. The non soluble partially hydrophilic film is preferably made out of thermoplastic starch materials.

The bio compostable adhesive used for laminating/attaching the bio compostable material to the substrate may be selected from compostable adhesive, PVAc (Polyvinyl Acetate), VAE (Vinyl Acetate Ethylene), PVOH (Polyvinyl Alcohol), Acrylics, PUD’s (Polyurethane dispersions), Starch and Dextrin, Casein, Cellulose solution adhesives, Natural and Synthetic Rubber Latex, Hot melts,either alone or combinations therefor any other raw material that fall under EN13432, ISO 17088:2008.

The biodegradable substrate and bio compostable material may be combined by layering, coating, impregnating or laminating resulting in the formation of a bio compostablemulti-layered composite with enhanced characteristics like strength and biocompatibility, which providing the soil with nutrients once the material has completely broken down by micro-organism.

Fig. 1.Illustrates the multilayered composite (3), wherein the biodegradable substrate (2) is coated with non-biodegradable material (1) such as polyethene(PE), polypropene (PP) or any other non biodegradablepolymer or petro plastic film forming polymer.

Fig. 2.illustrates the degradation of the known multi-layered composite (3) available in the priorart, wherein biodegradable substrate (2) of a specific percentage such as 90 gsm is coated with non-biodegradable material(1) of a specific percentage such as 10 gsm. Once the biodegradable substrate (2) is coated with non-biodegradable matrial(1) , said non-biodegradable material (1) gets absorbed on the biodegradablesubstrate (2), suchthat the molecules of the non-biodegradable material (1)binds to the cyclic chain of the biodegradable substrate (2). This chemical interaction of the biodegradable substrate (2) with the non-biodegradable material (1), results in formation of residue thus making the multi-layered material non-biodegradable in nature.

Fig. 3.illustrates the bio-compostable sustainable multilayered composite (6), wherein the biodegradable substrate (5) such as natural biodegradable materials like bio-degradable fibers, fabric, pulps like cotton, jute, hemp, bagasse, wood pulp and paper making materials may be used. Alternatively, the biodegradable substrate layer may be formed of naturally corrosive and subsequently bio-degradable metallic foils like aluminum foil, brass foil, copper foil, tin foil, steel foil and zinc foil is coated with bio compostable material (4) such as Polybutyleneadipate terephthalate (PBAT), Polyhydroxyalkanoates (PHAs), poly-3-hydroxybutyrate (PHB), polyhydroxyvalerate(PHV), polyhydroxyhexanoate (PHH), Polylactic acid (PLA), Polybutylene succinate (PBS), polycaprolactone (PCL), cellulose acetate, nitrocellulose, Polyanhydrides, Polyvinyl alcohol, Polysaccharides such as starch-based bioplastics, Proteins such as Gluten either alone or combinations thereof or any other raw material that fall under EN13432, ISO 17088:2008. Plastic products that provide proof of their compostability by successfully meeting the environmental condition falls under EN13432.

Fig. 4. illustrates the degradation of the bio-compostable sustainablemulti-layered composite (6) wherein the biodegradable substrate (5) is coated with bio compostable material (4) as disclosed in the present invention, wherein a biodegradable substrate(5) of a specific percentage such as 90 gsm is coated with bio compostable material(4) of a specific percentage such as 10 gsm. Once the biodegradable substrate (5) is coated with bio compostablematerial (4), said bio compostablematerial (4) gets absorbed on the biodegradable substrate (5), such that the molecules of the bio compostable material (4) binds to the biodegradable substrate (5). This molecular interaction of the biodegradable substrate with the bio compostable material, results in formation of a multi-layered composite (6), that is completely biodegradable in nature which in turn due to the presence of microorganism in the soil makes the biodegradable material, bio compostable in nature without leaving any residual waste on the soil. Thus increasing the fertility of the soil and enhancing the quality of soil.

The present invention comprises two perfectly compostable material, being brought together, in proportions to match the mechanical and tensile properties of presently available non compostable composites. This process of producing such a novel product can be done by coating, casting, laminating and extrusion of two compostable material, to get a standard % compostable, which is greater than or equal to at-least 91% compostable materials, as mandated in ISO 17088 or equivalent tests.

Problem solved by the present invention: This process of producing such a bio-compostable sustainable multilayered composite product, as known to persons skilled in the art, can be done by coating, casting, laminating and extrusion of two compostable material, to form a composite with specific mechanical and barrier properties. However, in the prior processes it has been observed that any process of combining two different substrates, results in “penetration” or “embedding” or “coating/impregnation” of one of the substrates, leaving behind residual waste, thereby making a degradable substrate into a non degradable composite. Further, if a coating of non degradablematerial that is less than 10 GSM (Grams per square meter), covers more weighted fibers of the compostable or degradable substrate, it renders the substrate to become non compostable.

Further, as mentioned in the prior art, if one of the substrates/material of coatings, is not degradable or compostable, then, as observed, the coating medium or resins, penetrate the fibers, thus embedding these fibers, with its residual properties of noncompostable chemistry.

For example,if paper which is made from various kinds of fibers, fibers which originate from sustainable sources, like wood, cotton, bamboo etc. will degrade naturally. But when a coating/ extrusion/ lamination of a non-degradable polymers, like PE, PVC, PET, HDPE, or solutions made from Polyurethane etc. is done then the perfectly natural and degradable fibers get contaminated/coated/impregnated by the polymer, thus converting the perfectly degradable material into non degradable/compostable.

Another example is Jute/Cotton Fabric, which is bio-degradable/compostable, till it is coated/laminated/externally affixed by a non-degradable polymer based material, results in negative impact on the environment, as the composite does not pass the norms of degradability/compostability.

According to a second aspect, the present invention provides schematic flow chart for methods of manufacturing bio compostable sustainable multi-layered composite by the methods such as (i) Blow film extrusion process; (ii) Cast film extrusion process;(iii) T-die extrusion coating process;(iv) calendaring coating process, (v) laminating process and subsequent coating.

Fig. 5. is a schematic flow chart for a direct method of manufacturing bio compostable multi-layered composite by casting molten bio compostable material/polymer through T-die extrusion coating process comprises the steps of:
- Feeding the bio compostable film forming material in the form of granules or pellets into the hopper;
- Subsequently passing the granules or pellets to the extruder barrel zone, wherein the pellets are melted or compacted, to achieve a molten stage, by maintaining the temperature of the extruder barrel at 150-170°C;
- Passing the molten polymer to the T-die, by maintained the temperature of die zone at 130 -160°C; wherein said T-die has a narrow horizontal exit opening for passing the melted bio compostable polymer in the form of thin flat horizontal films of meltedbio compostable polymer;
- Coating a thin film of molten bio compostable material/ polymer on the bio degradable substrate to form bio compostable multi-layered composite;
- passing the bio compostable multi-layered composite through a chiller roll, by maintaining the temperature at 10-30°C;
- Passing the bio compostable multi-layered composite after drying to the trimming unit, wherein the uneven sides are trimmed off;
- Cutting bio compostable multilayered composite in the form of rolls or film sheets for further use.

Fig. 6. Is a schematic flow chart for a direct method of manufacturing bio compostable multi-layered composite by casting molten bio compostable material/polymer through cast film extrusion process comprises the steps of:
- Feeding the bio compostable film forming material in the form of granules or pellets into the hopper;
- Subsequently passing the granules or pellets to the extruder barrel zone, wherein the pellets are melted or compacted, to achieve a molten stage, by maintaining the temperature of the extruder barrel at 150-170°C;
- Passing the molten polymer to the slot die, by maintained the temperature of die zone at 130 -180°C; wherein said slot die has a narrow horizontal exit opening for passing the molten polymer in the form of thin flat horizontal films of molten polymer;
- Casting the thin film of molten bio compostable material/ polymer on the bio degradable substrate at 110 -160°C
- passing the bio compostable multi-layered composite through a chiller roll, by maintaining the temperature at 10-30°C;
- Passing the bio compostable multi-layered composite after drying to the trimming unit, wherein the uneven sides are trimmed off;
- Cutting bio compostable multilayered composite in the form of rolls or film sheets for further use.

Fig. 7. Is a schematic flow chart for a direct method of manufacturing bio compostable multi-layered composite by casting molten bio compostable material/polymer through calendering coating process comprises the steps of:
- Feeding the bio compostable film forming material in the form of granules or pellets into the hopper;
- Subsequently passing the granules or pellets to the extruder barrel zone, wherein the pellets are melted or compacted, to achieve a molten stage, by maintaining the temperature of the extruder barrel at 150-170°C;
- Passing the molten polymer through a series of calendar roller unit , said calendar roller are a series of hard pressure roller used to finish or smooth a sheet of molten polymer into thin sheet/film of uniform thickness;
- Coating the thin film of molten bio compostable polymer on the bio degradable substrate
- passing the bio compostable multi-layered composite through a chiller roll, by maintaining the temperature at 10-30°C;
- Passing the bio compostable multi-layered composite after drying to the trimming unit, wherein the uneven sides are trimmed off;
- Cutting bio compostable multilayered composite in the form of rolls or film sheets for further use.

Fig. 8. Is a schematic flow chart for in direct method of manufacturing bio compostable multi-layered composite by laminating bio compostable material/polymer through blow film extrusion process comprises the steps of:
- Feeding the bio compostable film forming material in the form of granules or pellets into the hopper;
- Subsequently passing the granules or pellets to the extruder barrel zone, wherein the pellets are melted or compacted, to achieve a molten stage, by maintainingthe temperature of the extruder barrel at 150-170°C;
- Passing the molten polymer to the annular die, by maintained the temperature of die zone at 140-180°C;
- Simultaneously injecting air through a hole in the center of the die such that the pressure of the air causes the polymer film to expand into a bubble whereinair entering the bubble replaces air leaving it, so that even and constant pressure is maintained to ensure uniform thickness of the film ;
- Pulling the bubble formed in a continually upward direction from the die with the help of take off unit;
- Cooling the bubble formed with the help of cooling ring, such that the temperature of the bubble reduces, while maintaining the diameter of the bubble;
- wherein takeoff units such as guide tent (collapsing frame) pulls the bubble formed continuously in the upward direction, wherein the cooled bubbles ascends through a collapsing frame and is progressively collapsed between sets of roller or frames to form flat film;
- passing the film formed through a plurality of nip roller, that pull the film onto the windup roller; where the film is passed through plurality of winder such that the bio compostable materialuniformly adheres/laminates to at least one side of the said substrate with or without using any adhesive or heat;
- Cutting and sealing the bio compostable multilayered composite in the form of rolls used as film sheets for further use.

The bio compostable material manufactured by the above mentioned process may be selected from raw materials such as Polyhydroxyalkanoates (PHAs), poly-3-hydroxybutyrate (PHB), polyhydroxyvalerate(PHV), polyhydroxyhexanoate (PHH), Polylactic acid (PLA), Polybutylene succinate (PBS), polycaprolactone (PCL), cellulose acetate, nitrocellulose, Polyanhydrides, Polyvinyl alcohol, Polysaccharides such as starch-based bioplastics,Proteins such as Gluteneither alone or combinations thereofor any other raw material that fall under EN13432, ISO 17088:2008 standards.

The bio compostable material may be soluble in water, i.e. a water soluble film (WSF) or non soluble in water or partially non soluble that swell able under moisture and are bio compostable in nature. The WSF may be cold water soluble, warm water soluble, or hot water soluble. A partially hydrophilic film may be made out of non-hydrophilic materials, wherein at least one side may be cast with a water soluble film material and dried, to make the coated/cast side hydrophilic, to enable lamination with a biodegradable substrate with the aid of water. The non soluble partially hydrophilic film is preferably made out of thermoplastic starch materials.

The substrate used to manufacture the multilayered sustainable biocompostable composite may be selected from natural biodegradable materials like bio-degradable fibers, fabric, pulps like cotton, jute, hemp, bagasse, wood pulp. Alternatively, the biodegradable substrate layer may be formed of naturally corrosive and subsequently bio-degradable metallic foils like aluminum foil, brass foil, copper foil, tin foil, steel foil and zinc foil.

The bio compostable adhesive used for laminating/attaching the bio compostable film to the substrate may be selected from compostable EN13432 adhesive, PVAc (Polyvinyl Acetate), VAE (Vinyl Acetate Ethylene), PVOH (Polyvinyl Alcohol), Acrylics, PUD’s (Polyurethane dispersions), Starch and Dextrin, Casein, Cellulose solution adhesives, Natural and Synthetic Rubber Latex, Hot melts, either alone or combinations thereof.

Following experiments and results will give a proper perspective on the solution suggested by the present invention:

EXPERIMENT 1:

Bio compostable/Bio degradability analysis are performed under relevant IS standard such as ISO 17088 ( Bio Compostability), EN 13432 ( Bio Compostability), ISO 14855 (Ultimate biodegradation), EN 14046 ( in compost), ISO 17556 ( Ultimate bio degradation), ISO 11266 ( Soil quality), ISO 14851( Ultimate aerobic biodegrability), OECD 301C, OECD 301F, OECD 302C ( In fresh water) and ASTM D6691(in marine water):

A. PU COATED PAPER (Sample A): We coated a sheet of fibrous paper (made of bio degradable paper fibers) of 90 GSM, with 9 GSM of PU (polyurethane) resin. This formed a perfect multi-layered composite .The rheology of the PU resin chemistry embedded the fibers of the paper. We dried the sheet in oven by applying hot air (range of 90-100° C, for less than 7 minutes).The coat weight of coated sheet, after drying was 99 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 27.75 N/MM2, elongation was found to be 107%. Further 12 GSM of residual material has been observed in PU coated paper fiber in (Sample A), thus making it non compostable in nature.

B. SOLVENT ACRYLIC COATED PAPER (Sample B): We coated a sheet of fibrous paper (made of bio degradable paper fibers), of 90 GSM, with 8 GSM of ACRYLIC resin (Acrylate polymer’s ex. methyl acrylate). This formed a perfect multi-layered composite .The rheology of the resin chemistry embedded the fibers of the paper. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 98 GSM, denoting 8 GSM of coating, wherein tensile strength was found to be 28.73 N/MM2, elongation was found to be 109%.Further 10 GSM of Acrylic material has been observed as residual material in solvent acrylic coated paper fiber in (Sample B), thus making it non compostable in nature.

C. PU COATED COTTON FABRIC (Sample C): We coated a sheet of fibrous Cotton sheet (made of bio degradable cotton fibers) of 90 GSM, with 9 GSM of PU (polyurethane) resin. This formed a perfect multi-layered composite. The rheology of the PU resin chemistry embedded the fibers of the cotton sheet. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 99 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 29.23 N/MM2, elongation was found to be 106%. Further 14 GSM of PU material has been observed as residual material in PU coated cotton fabric (Sample C), thus making it non compostable in nature.

D. SOLVENT ACRYLIC RESIN COATED COTTON FABRIC (Sample D): We coated a sheet of fibrous Cotton sheet (made of bio degradable cotton fibers), of 90 GSM, with 7 GSM of solvent Acrylic resin. This formed a perfect multi-layered composite. The rheology of the resin chemistry embedded the fibers of the cotton sheet. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 97 GSM, denoting 7 GSM of coating, wherein tensile strength was found to be 28.34 N/MM2, elongation was found to be 105% . Further 11 GSM of acrylic material has been observed as residual material in Solvent acrylic resin coated cotton fabric.(Sample D), thus making it non compostable in nature.

E. BIO COMPOSTABLE RESIN COATED PAPER (Sample E): We coated a sheet of fibrous paper sheet (made of bio degradable paper fibers), of 90 GSM, with 9 GSM of Bio compostable polymer resins. This formed a perfect bio compostable multi-layered composite. The rheology of the Bio c chemistry embedded the fibers of the cotton sheet. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 99 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 29.55 N/MM2, elongation was found to be 109.5%. Further sample E is found to be completely bio compostable in nature, since no residues has been observed, other than that of inert fillers.

F. BIO COMPOSTABLE RESIN COATED COTTON FABRIC (Sample F): We coated a sheet of fibrous Cotton fabric (made of bio degradable cotton fibers), of 90 GSM, with 9 GSM of Bio compostable polymer resins. This formed a perfect bio compostable multi-layered composite.The rheology of the Bio c chemistry embedded the fibers of the cotton fabric. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 99 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 30.12 N/MM2, elongation was found to be 106%. Further sample F is found to be completely bio compostable in nature, since no residues has been observed.

G. NSNHFD COATED PAPER(Sample G): We coated a sheet of fibrous paper (made of bio degradable paper fibers), of 90 GSM, with 9 GSM of NSNHFD. This formed a perfectbio compostable multi-layered composite.The rheology of the NSNHFD chemistry embedded the fibers of the paper. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 99 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 32.55 N/MM2, elongation was found to be 108%. Further sample G is found to be completely bio compostable in nature, since no residues has been observed, other than that of inert fillers.

H. NSNHFD COATED COTTON FABRIC (Sample H): We coated a sheet of fibrous Cotton fabric (made of bio degradable cotton fibers), of 90 GSM, with 9 GSM of NSNHFD. This formed a perfectbio compostable multi-layered composite.,The rheology of the NSNHFD chemistry embedded the fibers of the cotton fabric. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 99 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 35.75 N/MM2, elongation was found to be 107%. Further sample H is found to be completely bio compostable in nature, since no residues has been observed..

I. BIO COMPOSTABLE RESIN COATED JUTE (Sample I): We coated a sheet of fibrous jute fabric (made of bio degradable jute fibers), of 120 GSM, with 9 GSM of bio compostable resin. This formed a perfect bio compostable multi-layered composite. The rheology of the bio compostable resin chemistry embedded the fibers of the jute fabric. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 129 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 29.34 N/MM2, elongation was found to be 106%. Further sample I is found to be completely bio compostable in nature, since no residues has been observed.

J. NSNHF COATED JUTE (Sample J): We coated a sheet of fibrous jute fabric (made of bio degradable jute fibers), of 120 GSM, with 9 GSM of NSNHF. This formed a perfect bio compostable multi-layered composite. The rheology of the NSNHFresin chemistry embedded the fibers of the jute fabric. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 129 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 31.21 N/MM2, elongation was found to be 108%. Further sample J is found to be completely bio compostable in nature, since no residues of NSNHF has been observed.

K. HWSF COATED PAPER (Sample K): We coated a sheet of fibrous paper fabric (made of bio degradable paper fibers), of 90 GSM, with 9 GSM of HWSF. This formed a perfect bio compostable multi-layered composite. The rheology of the HWSFresin chemistry embedded the fibers of the paper fabric. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 99 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 33.55 N/MM2, elongation was found to be 105%. Further sample K is found to be completely bio compostable in nature, since no residues of HWSF has been observed.

L. HWSF COATED COTTON PAPER (Sample L): We coated a sheet of fibrous cotton fabric (made of bio degradable cotton fibers), of 90 GSM, with 9 GSM of HWSF. This formed a perfect bio compostable multi-layered composite. The rheology of the HWSF resin chemistry embedded the fibers of the cotton fabric. We dried the sheet in oven by applying hot air (range of 90-100 C, for less than 7 minutes). The coat weight of coated sheet, after drying was 99 GSM, denoting 9 GSM of coating, wherein tensile strength was found to be 31.75 N/MM2, elongation was found to be 107%. Further sample L is found to be completely bio compostable in nature, since no residues of HWSF has been observed.

Test results:

The present invention discloses results in tabular format as disclosed below, which indicates the tensile strength, elongation capacity, residual percentage and compost ability/ bio degradability to understand the versatile characteristic of Bio-compostable sustainable multi-layered composite (herein referred as Bio-C) that has been obtained over the standard polymer film or biodegradable film obtained in the market:

Sr. No Samples (% of GSM) Tensile Strength in N/MM2 Elongation in % Bio degradability/Bio compostability Analysis
A PU Coated Paper 9 GSM + 90 GSM 27.75 107 Non Compostable and it has been observed 12 GSM of residual material (Paper fibers + PU)
B Solvent Acrylic coated Paper 8 GSM + 90 GSM 28.73 109 Non Compostable and it has been observed 10 GSM of Acrylic material in the residue material (Paper fiber + Solvent Acrylic).
C PU Coated Cotton Fabric 9 GSM + 90 GSM 29.23 106 Non Compostable and it has been observed 14 GSM of PU material in the residue.
D Solvent Acrylic resin coated Cotton Fabric 7 GSM + 90 GSM 28.34 105 Non Compostable and it has been observed 11 GSM of Acrylic material in the residue.
E Bio Compostable resin Coated Paper 9 GSM + 90 GSM 29.55 109.5 Bio Compostable and No residue has been observed, other than that of inert fillers.
F Bio Compostable resin Coated Cotton Fabric 9 GSM + 90 GSM 30.12 106 Bio Compostable composite. No residue has been observed.
G NSNHFD Coated Paper 9 GSM + 90 GSM 32.55 108 Bio Compostable and No residue has been observed, other than that of inert fillers.
H NSNHFD Coated Cotton Fabric 9 GSM + 90 GSM 35.75 107 Bio Compostable and No residue has been observed of the NSNHFD.
I Bio Compostable resin coated Jute 9 GSM + 120 GSM 29.34 106 Bio Compostable, No residue has been observed of the bio compostable resin.
J NSNHFDresin coated Jute 9 GSM + 120 GSM 31.21 108 Bio Compostable, No residue has been observed of the NSNHFD.
K HWSF Coated Paper 9 GSM + 90 GSM 33.55 105 Bio Compostable and No residue has been observed of the HWSF.

L HWSF Coated Cotton Fabric 9 GSM + 90 GSM 31.75 107 Bio Compostable and No residue has been observed of the HWSF.

From the above test results one can see that the Experiments A to D, have seen residual waste, which may also be termed as non-biodegradable or non-compostible, is higher than the actual application/coat weight of the polymer in question. This proves that the fibrous substrate of an otherwise degradable/compostible material has “received” the non-compostible polymer, during the lamination/coating process, and therefore proving our invention of a novel bio compatable multilayered composite.

Test Method-2

Further, the applicant has gone one step further, to prove its claims on “no residual waste obtained” in sample E to L, when compared to residual waste obtained in GSM in sample A to D. Wherein applicant has conducted a simple dissolution-acceleration test to prove the claims as set forth by experiment 1. Further, this dissolution-acceleration test not only allows us to gauge the amount of residual waste obtained but also helps us to better understand residual percentage and compost ability/ bio degradability that helps us to further understand the versatile characteristic of Bio-compostable sustainable multi-layered composite

EXPERIMENT 2:

Test method by dissolution—accelerated test.

Further applicant have conducted degradation test for above samples A to sample L as per Arrow’s method AGTL 2101, method is mentioned below:
Wherein in;
Step 1: Taking a 3 x 4 cm size sample of composite material (as disclosed in Sample A to Sample L) ;
Step 2: Dipping the sample of composite material in to the boiling ( < 100 degree celsius) water for 30 to 45 minutes with continuous stirring;
Step 3: Filtering the residue obtained of composite material (as disclosed in Sample A to Sample L) with 75 mesh filter ;
Step 4: Observing, the residue weight and the sedimented residue, after segregation.

Degradation test results are mentioned below:
Sr. No. Sample Substrate + Coating Analysis (residual sedimentation obtained)

A PU Coated Paper 9 GSM + 90 GSM It has been observed 12 GSM of PU coated fibrous material in the residue
B Solvent Acrylic coated Paper 8 GSM + 90 GSM It has been observed 10 GSM of Acrylic coated fibrous material in the residue.
C PU Coated Cotton Fabric 9 GSM + 90 GSM It has been observed 14 GSM of PU coated fibrous material in the residue.
D Solvent Acrylic resin coated Cotton Fabric 7 GSM + 90 GSM It has been observed 11 GSM of Acrylic coated fibrous material in the residue.
E Bio Compostable resin Coated Paper 9 GSM + 90 GSM No residue has been observed. Homogenous compostable sediments were observed.
F Bio Compostable resin Coated Cotton Fabric 9 GSM + 90 GSM No residue has been observed. Homogenous compostable sediments were observed.
G NSNHFD Coated Paper 9 GSM + 90 GSM No residue has been observed of the NSNHFD.

H NSNHFD Coated Cotton Fabric 9 GSM + 90 GSM No residue has been observed of the NSNHFD.
I Bio Compostable resin coated Jute 9 GSM + 120 GSM No residue has been observed of the bio compostable resin.
J NSNHFD resin coated Jute 9 GSM + 120 GSM No residue has been observed of the NSNHFD.

K HWSF Coated Paper 9 GSM + 90 GSM No residue has been observed of the HWSF.

L HWSF Coated Cotton Fabric 9 GSM + 90 GSM No residue has been observed of the HWSF.

It has been found that in sample A, when substrate such as a sheet of fibrous paper (made of bio degradable paper fibers) is coated with PU (polyurethane) resin., tensile strength is found to 27.75N/MM2, elongation in percentage is found to be 107%, 12 GSM of residual material has been observed in PU coated paper fiber in (Sample A). In sample B, when substrate such as a sheet of fibrous paper (made of bio degradable cotton fibers) is coated with ACRYLIC resin., tensile strength is found to 28.73N/MM2, elongation in percentage is found to be 109%, 10 GSM of Acrylic material has been observed as residual material in solvent acrylic coated paper fiber in (Sample B). In sample C, when substrate such as a sheet of cotton sheet (made of bio degradable cotton fibers) is coated with PU (polyurethane) resin, tensile strength is found to 29.23N/MM2, elongation in percentage is found to be 106%, 14 GSM of PU material has been observed as residual material in PU coated cotton fabric (Sample C). In sample D, when substrate such as a sheet of cotton sheet (made of bio degradable cotton fibers) is coated with ACRYLIC resin, tensile strength is found to 28.34N/MM2, elongation in percentage is found to be 105%,11 GSM of acrylic material has been observed as residual material in Solvent acrylic resin coated cotton fabric.(Sample D).
Similarly, in sample E, when substrate such as a sheet of fibrous paper sheet (made of bio degradable paper fibers) is coated with Bio compostable resins, tensile strength is found to 29.55N/MM2, elongation in percentage is found to be 109.5%, no residue was observed in (sample E) other than inert fillers. In sample F, when substrate such as a sheet of cotton fabric (made of bio degradable cotton fibers) is coated with Bio compostable resins, tensile strength is found to 30.12N/MM2, elongation in percentage is found to be 106%, no residue was observed in (sample F). In sample G, when substrate such as a sheet of fibrous cotton paper (made of bio degradable cotton fibers) is coated with NSNHFD, tensile strength is found to 32.55N/MM2, elongation in percentage is found to be 108%, no residue was observed in (sample G) other than inert fillers. In sample H, when substrate such as a sheet of fibrous cotton fabric (made of bio degradable cotton fibers) is coated with NSNHFD, tensile strength is found to 35.75N/MM2, elongation in percentage is found to be 107%, no residue was observed in (sample H). In sample I, when substrate such as a sheet of fibrous jute fabric (made of bio degradable jute fibers) is coated with bio compostable resin, tensile strength is found to 29.34N/MM2, elongation in percentage is found to be 106%, no residue was observed in (sample I). In sample J, when substrate such as a sheet of fibrous jute fabric (made of bio degradable jute fibers) is coated with NSNHF, tensile strength is found to 31.21N/MM2, elongation in percentage is found to be 108%, no residue was observed in (sample J). In sample K, when substrate such as a sheet of fibrous paper fabric (made of bio degradable paper fibers) is coated with HWSF , tensile strength is found to 33.55N/MM2, elongation in percentage is found to be 105%, no residue was observed in (sample K). In sample L, when substrate such as a sheet of fibrous cotton fabric (made of bio degradable cotton fibers) is coated with HWSF , tensile strength is found to 31.75N/MM2, elongation in percentage is found to be 107%, no residue was observed in (sample L).
Thus from the Bio compostable/Bio degradability analysisas disclosed in experiments 1 and dissolution—accelerated test as disclosed in experiment 2 above, in an average, it may be concluded that bio degradable cotton fibers, when coated with Bio C or NSNHFD or HWSF bio compostable film as shown in sample E to sample L showed better tensile strength, elongation property and surprisingly showed complete bio compostability with no residual waste when compared to tensile strength and elongation property as disclosed in standard sample A to Sample D. Further, it can be seen that sample E to sample L are completely bio compostable/bio degradable, when compared to sample A to sample D which are non compostable or non bio degradable in nature as seen in the dissolution—accelerated test disclosed in experiment 2.The present invention not only discloses better tensile and elongation property but exceptionally shows bio compostability with no residual waste when compared to the already available standard bio degradable/non-bio degradable multi-layered composite in the market.
In conclusion the present invention has application to various types of substrates while retaining stretch ability of the substrate and elasticity of the bio compostable water soluble/non soluble hydrophilic film and simultaneously enhancing the physical characteristics like tensile, tear, puncture resistance, burst factor, and breaking strength of the resulting bio compostable material, that does not leaves residual waste.

The bio-compostable multi-layered composite may have several application such as banners, packaging, can be used in composite system, as manure and may find many more application in the packaging domain.

The above description is intended to describe the preferred embodiments of the invention in sufficient detail to enable those skilled in the art to practice the invention. The above description is intended to be illustrative and should not be interpreted as limiting the scope of the invention. Those skilled in the art to which the invention relates will appreciate that many variations of the described example implementations and other implementations exist within the scope of the claimed invention.
,CLAIMS:We Claim:

1. A bio-compostable sustainable multi-layered composite comprising:
- a bio degradable substrate layer and
- a bio-compostable material that uniformly coated and adhered to at least one side of the said bio degradable substrate with or without using any bio compostable adhesive;
Characterized in that, said bio compostable sustainable multi-layered composite shows better mechanical and barrier properties and also when it degrades/decomposes it acts as a compost without leaving any residual waste.

2. The bio compostable sustainable multilayered composite as claimed in claim 1, wherein the biodegradable substrate layer is formed of natural biodegradable materials like bio-degradable fibers, fabric, pulps like cotton, jute, hemp, bagasse, wood pulp and paper making materials.

3. The bio compostable sustainable multilayered composite as claimed in claim 1, wherein the biodegradable substrate layer is optionally formed of metal foil comprises an aluminum foil, brass foil, copper foil, tin foil, steel foil and zinc foil.

4. The bio compostable sustainable multilayered composite as claimed in claim 1, wherein the bio compostable material is made from raw materials selected from acrylic acid polymers, acrylic ester polymers, acrylic acid copolymers, acrylic ester copolymers, copolymers of acrylic acids and esters, crosslinked polyvinyl alcohols, crosslinked cellulose derivatives, ethyl cellulose, nitrocellulose, cellulose butyrate, cellulose acetate butyrate, ethylene vinyl alcohol, ethylene vinyl acetate, polyvinyl acetate, polyvinylidene chloride, natural and synthetic waxes, polyurethanes or modified polyvinyl alcohols.

5. The bio compostable sustainable multilayered composite as claimed in claim 1, wherein the bio compostable materials is water soluble film (WSF) or non soluble in water or partially non soluble in nature.

6. The bio compostable sustainablemultilayered composite as claimed in claim 1, wherein the water soluble/non soluble/partially non soluble hydrophilic film is made of one or more raw materials including Polyhydroxyalkanoates (PHAs), poly-3-hydroxybutyrate (PHB), polyhydroxyvalerate(PHV), polyhydroxyhexanoate (PHH), Polylactic acid (PLA), Polybutylene succinate (PBS), polycaprolactone (PCL), cellulose acetate, nitrocellulose, Polyanhydrides, Polyvinyl alcohol, Polysaccharides such as starch-based bio plastics, Proteins such as Gluteneither alone or combinations thereof.

7. The bio compostable sustainable multilayered composite as claimed in claim 1, wherein the bio compostable material is water soluble film (WSF) are cold water soluble, warm water soluble, or hot water soluble or Non soluble hot water soluble film or hybrid in nature.

8. The bio compostable sustainable multilayered composite as claimed in claim 1, wherein the bio compostable material is non-soluble, hybrid, partially hydrophilic film made out of thermoplastic starch materials.

9. The bio compostable sustainable multilayered composite as claimed in claim 1 wherein the bio compostable material is a partially non soluble hydrophilic film, which may be cast with water soluble film materials on at least one side of the film.

10. The bio compostable sustainable multilayered composite as claimed in claim 1, wherein the bio compostable film swells under moisture and are bio compostable in nature.

11. The bio compostable sustainable multilayered composite as claimed in claim 1 wherein the bio compostable adhesive used are selected from compostable adhesive, PVAc (Polyvinyl Acetate), VAE (Vinyl Acetate Ethylene), PVOH (Polyvinyl Alcohol), Acrylics, PUD’s (Polyurethane dispersions), Starch and Dextrin, Casein, Cellulose solution adhesives, Natural and Synthetic Rubber Latex, Hot melts either alone or combinations thereof.

12. The bio compostable sustainable multilayered composite as claimed in claim 1, wherein the said substrate and water soluble/non soluble hydrophilic film are combined by layering, coating, impregnating or laminating.

13. A direct method of manufacturing a bio compostable sustainable multilayered composite as claimed in claim 1, by casting molten bio compostable material/polymer using T-die extrusion coating process comprising the steps of:
- Feeding the raw material in the form of granules or pellets into the hopper;
- passing the granules or pellets to the extruder barrel zone, wherein the pellets are melted or compacted, to achieve a molten stage, by maintaining the temperature of the extruder barrel at 150-170°C;
- Passing the molten polymer to the T-die, by maintained the temperature of die zone at 130 -160°C; wherein said T-die has a narrow horizontal exit opening for passing the molten polymer in the form of thin flat horizontal films of molten polymer;
- Coating the molten bio compostable material/polymer on the bio degradable substrate
- passing the bio compostable multi-layered through a chiller roll, by maintaining the temperature at 10-30°C;
- Passing the bio compostable multi-layered after drying to the trimming unit, wherein the uneven sides are trimmed off; and
- Cutting bio compostable multilayered composite in the form of rolls or film sheets for further use.

14. A direct method of manufacturing a bio compostable sustainable multilayered composite as claimed in claim 1, by casting molten bio compostable material/polymer using cast film extrusion process comprising the steps of:
- Feeding the raw material in the form of granules or pellets into the hopper;
- Subsequently passing the granules or pellets to the extruder barrel zone, wherein the pellets are melted or compacted, to achieve a molten stage, by maintaining the temperature of the extruder barrel at 150-170°C;
- Passing the molten polymer to the slot die, by maintained the temperature of die zone at 130 -180°C; wherein said slot die has a narrow horizontal exit opening for passing the molten polymer in the form of thin flat horizontal films of molten polymer;
- Casting the molten bio compostable material/polymer on the bio degradable substrate at 110 -160°C
- passing the bio compostable multi-layered composite through a chiller roll, by maintaining the temperature at 10-30°C;
- Passing the bio compostable multi-layered composite after drying to the trimming unit, wherein the uneven sides are trimmed off; and ,Cutting bio compostable multilayered composite in the form of rolls or film sheets for further use.

15. A direct method of manufacturing a bio compostable sustainable multilayered composite as claimed in claim 1, by casting molten bio compostable material/polymer using calendering coating process comprising the steps of:
- Feeding the bio compostable film forming material in the form of granules or pellets into the hopper;
- Subsequently passing the granules or pellets to the extruder barrel zone, wherein the pellets are melted or compacted, to achieve a molten stage, by maintaining the temperature of the extruder barrel at 150-170°C;
- Passing the molten polymer through a series of calendar roller unit , said calendar roller are a series of hard pressure roller used to finish or smooth a sheet of molten polymer into thin sheet/film of uniform thickness;
- Coating the molten bio compostable polymer on the bio degradable substrate
- passing the bio compostable multi-layered composite through a chiller roll, by maintaining the temperature at 10-30°C;
- Passing the bio compostable multi-layered composite after drying to the trimming unit, wherein the uneven sides are trimmed off:
- Cutting bio compostable multilayered composite in the form of rolls or film sheets for further use.

16. An indirect method of manufacturing a bio compostable sustainable multilayered composite as claimed in claim 1, by laminating bio compostable material/polymer using blow film extrusion process comprising the steps of:
- Feeding the bio compostable film forming material in the form of granules or pellets into the hopper;
- Subsequently passing the granules or pellets to the extruder barrel zone, wherein the pellets are melted or compacted, to achieve a molten stage, by maintainingthe temperature of the extruder barrel at 150-170°C;
- Passing the molten polymer to the annular die, by maintained the temperature of die zone at 140-180°C;
- Simultaneously injecting air through a hole in the center of the die such that the pressure of the air causes the polymer film to expand into a bubblewhereinair entering the bubble replaces air leaving it, so that even and constant pressure is maintained to ensure uniform thickness of the film ;
- Pulling the bubble formed in a continually upward direction from the die with the help of take off unit;
- Cooling the bubble formed with the help of cooling ring, such that the temperature of the bubble reduces, while maintaining the diameter of the bubble;
- wherein takeoff units such as guide tent (collapsing frame) pulls the bubble formed continuously in the upward direction, wherein the cooled bubbles ascends through a collapsing frame and is progressively collapsed between sets of roller or frames to form flat film;
- passing the film formed through a plurality of nip roller, that pull the film onto the windup roller; where the film is passed through plurality of winder such that the bio compostable material uniformly adheres/laminates to at least one side of the said substrate with or without using any adhesive or heat;
- Cutting and sealing the bio compostable multilayered composite in the form of rolls used as film sheets for further use.

17. The method as claimed in claims 13 to 16, wherein the temperature of the extruder barrel zone is maintained at a temperature of 120-230°C.

18. The method as claimed in claims 13 to 16, wherein the temperature of the extruder barrel zone is preferably maintained at a temperature of 140-190°C.

19. The method as claimed in claims 13 to 16, wherein the temperature of the extruder barrel zone is more preferably maintained at a temperature of 150-170°C.

20. The method as claimed in claims 13 to 16, wherein the temperature of the die zone is maintained at a temperature of 140 -230°C.

21. The method as claimed in claims 13 to 16, wherein the temperature of the die zone is preferably maintained at a temperature of 150 -190°C.

22. The method as claimed in claims 13 to 16, wherein the temperature of the die zone is more preferably maintained at a temperature of 160 -180°C.

23. The method as claimed in claims 13 to 16, wherein the biodegradable substrate layer is formed of natural biodegradable materials like bio-degradable fibers, fabric, pulps like cotton, jute, hemp, bagasse, wood pulp.

24. The method as claimed in claims 13 to 16, wherein the biodegradable substrate layer is preferably formed of metal foil comprises an aluminum foil, brass foil, copper foil, tin foil, steel foil and zinc foil.

25. The method as claimed in claims 13 to 16, wherein the bio compostable material is made from raw materials selected from acrylic acid polymers, acrylic ester polymers, acrylic acid copolymers, acrylic ester copolymers, copolymers of acrylic acids and esters, crosslinked polyvinyl alcohols, crosslinked cellulose derivatives, ethyl cellulose, nitrocellulose, cellulose butyrate, cellulose acetate butyrate, ethylene vinyl alcohol, ethylene vinyl acetate, polyvinyl acetate, polyvinylidene chloride, natural and synthetic waxes, polyurethanes or modified polyvinyl alcohols.

26. The method as claimed in claims 13 to 16, wherein the bio compostable material is water soluble film (WSF) or non-soluble in water or hybrid or partially non soluble in nature.

27. The method as claimed in claims 13 to 16, wherein the bio compostable material swell able under moisture and are bio compostable in nature.

28. The method as claimed in claims 13 to 16, wherein the bio compostable material is water soluble film (WSF) are cold water soluble, warm water soluble, or hot water soluble or Non soluble hot water soluble film or hybrid in nature.

29. The method as claimed in claims 13 to 16, wherein the bio compostable material is non-soluble, partially hydrophilic film made out of thermoplastic starch materials.

30. The method as claimed in claims 13 to 16, wherein the water soluble/non soluble/partially non soluble hydrophilic film is made of one or more raw materials including Polyhydroxyalkanoates (PHAs), poly-3-hydroxybutyrate (PHB), polyhydroxyvalerate(PHV), polyhydroxyhexanoate (PHH), Polylactic acid (PLA), Polybutylene succinate (PBS), polycaprolactone (PCL), cellulose acetate, nitrocellulose, Polyanhydrides, Polyvinyl alcohol, Polysaccharides such as starch-based bio plastics, Proteins such as Gluteneither alone or combinations thereof.

31. The method as claimed in claims 13 to 16, wherein the bio compostable material is a partially non soluble hydrophilic film, which may be cast with water soluble film materials on at least one side of the film.

32. The method as claimed in claims 13 to 16, wherein the said substrate and water soluble/non soluble hydrophilic film are combined by layering, coating, impregnating or laminating.