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Case Study

Case Study – Solving High-Strength Packaging Challenges in the Automotive Fasteners Industry Using Compostable Plastics

Industry – Automotive Fasteners (Bolts & Nuts)
Application – Primary packaging for heavy-weight automotive fasteners with sharp edges

Load per bag: 10–14 kg

Problem

Automotive fasteners require high-strength primary packaging due to their heavy weight, sharp edges, and rough handling across the supply chain. Traditionally, thick LDPE films (120 micron) were used to prevent tearing, puncture, and failures during transport. Although the fasteners industry wanted to shift toward compostable packaging, conventional compostable plastics failed to meet the required mechanical performance. Over one year, multiple trials with 5+ compostable plastic manufacturers across India were unsuccessful due to: r packaging.
  • Insufficient tensile strength
  • Poor notch impact resistance caused by sharp metal edges
  • Frequent tearing during handling and transit
This created a strong belief in the industry that compostable plastics are not suitable for heavy-duty fastener packaging.

TGP’s Approach & Technical Solution

TGP approached the problem from a polymer-engineering perspective, rather than a material substitution mindset. Key Technical Challenges Addressed:
  • High load requirement (8–14 kg per bag)
  • Sharp edges causing notch-induced failure
  • Replacement of 120-micron LDPE film without increasing cost

Solution

  • Developed a high-strength compostable film achieving >25 MPa tensile strength, exceeding the performance of the LDPE film previously used
  • Enhanced notch impact strength to withstand sharp automotive bolts and nuts
  • Used reactive extrusion techniques for:
  • Chain extension
  • Compatibilisation
  • Ensured all base carriers and modifiers remained fully compostable, complying with IS 17088
  • Updated Processing techniques to increase the productivity while maintaining the material performance.

Cost Optimization

  • Successfully replaced 120-micron LDPE with a 65-micron compostable film

Implementation & Validation

  • Conducted 3 rigorous trial cycles
  • Packaging tested across the supply chain of three different manufacturing plants of one of India’s leading automobile manufacturers
  • Evaluated and approved by:
  • Plant Head
  • Quality Control Head
  • Supply Chain Manager
  • Packaging Manager
  • Customer’s internal technical team

Result – Cost Optimization

  • More than 10 MT of LDPE packaging replaced in the last 12 months for this single fastener customer
  • Zero rejections observed across production, storage, and transit from the 2nd month of implementation.
  • Packaging running successfully for over one year
  • Demonstrated that compostable plastics can meet heavy-duty industrial requirements when engineered correctly
  • Enabled the customer to meet sustainability goals without compromising performance or costs.