Polyurethane prepolymer-modified high-content starch-PBAT films

Starch as a smart, cheap, and green gatekeeper for the controlled release of propyl gallate from antioxidant biodegradable packaging films

Oxidative rancidity of food products and massive consumption of plastic packaging have put the necessity in manufacturing novel antioxidant biodegradable packaging films. A comprehensive investigation was conducted on starch/poly(butylene adipate-co-terephthalate) (PBAT) antioxidant blown films, in which starch acted as a gatekeeper for the controlled release of propyl gallate (PG). PG was well integrated into the matrices and bound to starch molecules by hydrogen bonding. All films showed strong anti-ultraviolet performance, and higher oxygen barrier than the traditional polyethylene film. Increasing starch proportions promoted the swelling of films and the release of PG, thereby causing higher antioxidant activity at the same contact time to free radical solutions. Similar polarity made PG prone to partition and rapid migration into the food simulants with higher ethanol concentration and the high-fat-content peanut butter. The film with 20:80 w/w starch/PBAT proportion and 3% w/w PG content effectively suppressed the oxidation of peanut butter within 300-day storage. Findings demonstrated this strategy for manufacturing starch/PBAT antioxidant films as a long-term active packaging in food industry.

Sugar/sugar alcohol with glycerol as co-plasticizers for high-content starch/PBAT blown films: from fine structure to physicochemical properties

BACKGROUND

Glycerol is a well-known plasticizer for starch-based materials, but it easily migrates during starch retrogradation, thereby deteriorating the films' properties. We hypothesized that the performance of high-content starch/poly(butylene adipate-co-terephthalate) (PBAT) films could be enhanced by using sugar/sugar alcohol (glucose, sucrose and sorbitol) as natural, green and edible co-plasticizers with glycerol.

RESULTS

The employment of co-plasticizers reduced the melt fluidity of the blends, established intermolecular hydrogen bonds with starch and resulted in a brittle film structure. The presence of sucrose contributed to the formation of more B-type starch crystals. Glucose and sucrose promoted the conversion of bound water to entrapped water, while sorbitol contributed to more bound water. The co-plasticizers enhanced films' thermal stability, moisture permeability (from 3.61 to 3.72 × 10-11 g m m-2 s-1 Pa-1), and oxygen barrier (from 12.84 to 8.74 × 10-13 cm3 cm cm-2 s-1 Pa-1). Glucose/glycerol co-plasticized film had the maximum tensile strength (10.12 MPa), and sucrose/glycerol co-plasticized film showed the highest Young's modulus (380.31 MPa).

CONCLUSION

Sorbitol with linear structure and the lowest melting point exhibited a plasticizing capacity similar to glycerol. The molecular structure (linear or cyclic), hydroxyl group proportion and melting point of the sugar/sugar alcohol were the key factors to regulate the fine structure and properties of starch/PBAT films. © 2024 Society of Chemical Industry.

A biodegradable pH-response packaging film with blueberry extract: Blown-extrusion fabrication, multifunctional activity, and kinetic investigation

This work proposed a novel strategy for manufacturing biodegradable pH-response packaging. Briefly, to minimize the amount and thermal processing times of blueberry extract (BE), ethanol-dissolved BE (≤ 3‰ w/w) was sprayed onto the starch/poly(butylene adipate-co-terephthalate) (PBAT) pellets before extrusion blowing. BE was well-integrated into the matrix, forming uniformly colored films. The films with BE exhibited superior mechanical (7.85 MPa of strength, 606.53% of elongation) and enhanced barrier capabilities against ultraviolet light, moisture, and gas. Additionally, they exhibited good antioxidant capacity (68.69%), antibacterial activity (72.40%), and maintained color stability. The film with 3‰ w/w BE presented excellent color responsiveness (ΔE⁎ ≥ 15) in the alkaline range, and successfully monitored the spoilage of shrimp. The pigments in the film had the maximum migration degree (≥ 70%) and rate in 50% ethanol simulation, following a first-order kinetic behavior dominated by Fickian diffusion. Findings supported the application of this strategy in the fabrication of starch/PBAT/BE films for pH-response intelligent packaging.

Starch-based biodegradable composites: Effects of in-situ re-extrusion on structure and performance

In this study, starch-based biodegradable composites (SDC) were prepared by extruding using thermoplastic starch (TPS, 65%wt), polylactic acid (PLA, 30%wt) and poly (butylene adipate co-terephthalate) (PBAT, 5%wt). Structure and properties of the SDC were compared by performing 1-, 2-, 3-times extrusion. The results show that in-situ re-extrusion refines the TPS in composites and reduces the size of the phase. As the number of extrusions increases, the ester bond of composites at 868 cm-1 disappears, the crystallinity increases, and the thermal stability decreases. Among the three types of composites, the mechanical properties and hydrophobic properties of the material obtained by the 2-times are the most outstanding. Compared with SDC, the elongation at break and Young's modulus of SDC-2 are significantly increased, with an increase of 8.01 % and 1.28 % in the machine direction and an increase of 11.02 % and 1.79 % in the transverse direction respectively. Additionally, water contact angle range of SDC-2 from 98.7° to 101.7°. Therefore, SDC prepared by 2-times in-situ re-extrusion has the best film properties and is an ideal packaging material. This study presents a novel method for fabricating starch-degradable composite films by in-situ re-extrusion, providing new insights into the development of starch packaging materials.

Development of cinnamon essential oil-loaded PBAT/thermoplastic starch active packaging films with different release behavior and antimicrobial activity

The poly (butylene adipate-co-terephthalate)/thermoplastic starch (PBAT/TPS) active packaging films containing cinnamon essential oil (CEO) were fabricated by melting blending and extrusion casting method. The effects of TPS content (0 %, 10 %, 20 %, 30 %, 40 % and 50 %) on the properties of the films and their application in largemouth bass preservation were studied. As TPS content increased from 0 % to 50 %, the water vapor permeability increased from 7.923 × 10-13 (g•cm/(cm2•s•Pa)) to 23.967 × 10-13 (g•cm/(cm2•s•Pa)), the oxygen permeability decreased from 8.642 × 10-11 (cm3•m/(m2•s•Pa)) to 3.644 × 10-11 (cm3•m/(m2•s•Pa)), the retention of CEO in the films increased. The release rate of CEO from the films into food simulant (10 % ethanol) accelerated with increasing TPS. The films exhibited different antibacterial activity against E. coli, S. aureus, and S. putrefaciens. It was closely related with the release behavior of the CEO. The films containing CEO could efficiently inhibit the decomposition of protein and the growth of microorganisms in largemouth bass. It showed that the higher TPS in the films, the better inhibitory effect. This study provided a new idea for developing PBAT/TPS active films with different release behavior of active agents and different antibacterial activity for food packaging.

Starch/poly (butylene adipate-co-terephthalate) blown films contained the quaternary ammonium salts with different N-alkyl chain lengths as antimicrobials

Antimicrobial biodegradable packaging is in high demand as a one-two punch against microbiological and plastic hazards. Two quaternary ammonium salts (QAS) with different N-alkyl chain lengths were used for starch/poly (butylene adipate-co-terephthalate) (PBAT) blown antimicrobial films. Dioctadecyl dimethyl ammonium chloride (D1821) contributed to a homogeneous film morphology at 5% w/w level, while micro-pores occurred with didodecyl dimethyl ammonium chloride (D1221). Increasing QAS content weakened hydrogen bonding interactions. D1821 promoted the formation of intercalated structure of nano-clays, and improved the strength, thermal stability, barrier, and surface hydrophobicity of the films. Conversely, adding D1221 decreased the mechanical properties, and significantly enhanced the surface hydrophilicity. The films with 3% and 5% w/w D1221 obviously inhibited the growth of both Staphylococcus aureus and Escherichia coli, while those with D1821 cannot show clear zone against the Gram-negative. 5% w/w D1221-loaded film delayed the growth of microorganisms in beef, of which the total viable count was 5.75 lg CFU/g after 21-day chilling storage. Findings supported that QAS had the potential for manufacturing starch/PBAT antimicrobial packaging, but the release kinetics and cytotoxicity still need to be systematically explored before application.

Cross-linked poly(ester urethane)/starch composite films with high starch content as sustainable food-packaging materials: Influence of cross-link density

This study focused on the development of cross-linked poly(ester urethane)/starch (PEUST) composites containing 50 wt% starch content for food-packaging materials. The NCO-terminated poly(caprolactone-urethane) prepolymer (PCUP) was first synthesized through bulk condensation. Then, low-moisture starch (0.21 wt%) and PCUP-based PEUST films were fabricated through an intensive extrusion process, followed by thermo-compression molding. The chemical structure of PCUP and PEUST was confirmed using Fourier transform infrared spectroscopy. Moreover, a comprehensive evaluation was conducted to assess the influence of cross-link density on the physicochemical properties of the composite films. The results showed that an increase in the cross-link density within the composites improved component compatibility and tensile strength but reduced crystallinity, water sensitivity, hydrolytic degradability, and water vapor permeability (WVP) of the films. In addition, the cytotoxicity tests were conducted to evaluate the safety of the composite films, and the high cell viability demonstrated non-toxicity for food application. The PEUST-II films with moderate cross-link density exhibited a suitable degradation rate (27.7 % weight loss at degradation for 140 d), optimal tensile properties (tensile strength at break: 12.4 MPa; elongation at break: 352 %), and low WVP (68.4 g/(m2⋅24h) at 30 % relative humidity). These characteristics make them highly promising as fresh-keeping food packaging.

Toughening Enhancement Mechanism and Performance Optimization of Castor-Oil-Based Polyurethane Cross-Linked Modified Polybutylene Adipate/Terephthalate Composites

In this study, polyol castor oil (CO) and toluene-2,4-diisocyanate (TDI) were selected to modify PBAT, and castor-oil-based polyurethane (COP) was produced in a PBAT matrix using melt-blending and hot-pressing technology to study the effect of network cross-linking structure on various properties of bio-based polyester PBAT, aiming to introduce CO and TDI to improve the mechanical properties of composite materials. The results showed that when the total addition of CO and TDI was 15%, and the ratio of the hydroxyl group of CO to the isocyanate group of TDI was 1:1, the mechanical properties were the best. The tensile strength of the composite was 86.19% higher than that of pure PBAT, the elongation at break was 70.09% higher than that of PBAT, and the glass transition temperature was 7.82 °C higher than that of pure PBAT. Therefore, the composite modification of PBAT by CO and TDI can effectively improve the heat resistance and mechanical properties of PBAT-based composites.

Effects of co-plasticization of glycerol and small molecular esters on the physicochemical properties of extrusion-blown high-content starch/poly(butylene adipate-co-terephthalate) films

BACKGROUND

Poor mechanical and water barrier properties of starch-based films severely restrict their applications as packaging materials. In this study, glycerol was combined with various small molecular esters (SMEs) with different molecular structures to plasticize high-content starch/poly(butylene adipate-co-terephthalate) (80/20, w/w) films (SPFs) prepared by extrusion blowing. The effects of co-plasticization on the physicochemical properties and film-forming mechanism of SPFs were investigated.

RESULTS

The addition of glycerides to SPFs reduced intermolecular interaction, increased molecular chain mobility, and decreased glass transition, melting temperatures, and crystallinity. Mechanical and water barrier properties of SPFs were improved significantly with the co-plasticization of glycerol and SMEs. The incorporation of triacetate glyceride increased tensile strength of SPFs by 54% and the water contact angle by up to 95°. The SPF with diacetate glyceride exhibited the minimum water vapor permeability, which decreased by 39%.

CONCLUSION

The levels of hydrophilic/hydrophobic groups in SMEs and their molecular weights were essential for the plasticizing effects. Glycerides tended to infiltrate into starch for effective plasticization compared with citrates. The combination of glycerol and glycerides had better plasticizing effects on starch. © 2023 Society of Chemical Industry.

Essential characteristics improvement of metallic nanoparticles loaded carbohydrate polymeric films - A review

Petroleum-based films have contributed immensely to various environmental issues. Developing green-based films from carbohydrate polymers is crucial for addressing the harms encountered. However, some limitations exist on their property, processibility, and applicability that prohibit their processing for further developments. This review discusses the potential carbohydrate polymers and their sources, film preparation methods, such as solvent-casting, tape-casting, extrusion, and thermo-mechanical compressions for green-based films using various biological polymers with their merits and demerits. Research outcomes revealed that the essential characteristics improvement achieved by incorporating different metallic nanoparticles has significantly reformed the properties of biofilms, including crystallization, mechanical stability, thermal stability, barrier function, and antimicrobial activity. The property-enhanced bio-based films made with nanoparticles are potentially interested in replacing fossil-based films in various areas, including food-packaging applications. The review paves a new way for the commercial use of numerous carbohydrate polymers to help maintain a sustainable green environment.

Biodegradable active packaging: Components, preparation, and applications in the preservation of postharvest perishable fruits and vegetables

The consumption of fresh fruits and vegetables is restricted by the susceptibility of fresh produce to deterioration caused by postharvest physiological and metabolic activities. Developing efficient preservation strategies is thus among the most important scientific issues to be urgently addressed in the field of food science. The incorporation of active agents into a polymer matrix to prepare biodegradable active packaging is being increasingly explored to mitigate the postharvest spoilage of fruits and vegetables during storage. This paper reviews the composition of biodegradable polymers and the methods used to prepare biodegradable active packaging. In addition, the interactions between bioactive ingredients and biodegradable polymers that can lead to plasticizing or cross-linking effects are summarized. Furthermore, the applications of biodegradable active (i.e., antibacterial, antioxidant, ethylene removing, barrier, and modified atmosphere) packaging in the preservation of fruits and vegetables are illustrated. These films may increase sensory acceptability, improve quality, and prolong the shelf life of postharvest products. Finally, the challenges and trends of biodegradable active packaging in the preservation of fruits and vegetables are discussed. This review aims to provide new ideas and insights for developing novel biodegradable active packaging materials and their practical application in the preservation of postharvest fruits and vegetables.

Rational formulations of sustainable polyurethane/chitin/rosin composites reinforced with ZnO-doped-SiO2 nanoparticles for green packaging applications

Polysaccharide chitin (CH) was modified by antimicrobial natural gum rosin as a biocompatible agent within the thermoplastic polyurethane (TPU) elastomer to form the TPU/CH composite. This blend was then mixed with different ratios of ZnO-doped-SiO₂ nanoparticles (ZnO-SiO₂-NPs) to chelate chitin and to improve the properties of TPU nanocomposites. The topology and surface roughness of chitin and nanoparticles within the TPU matrix, besides their effect on the crystallinity degree of TPU were characterized by scanning electron microscopy (SEM), atomic force microscopy (AFM), and X-ray diffraction (XRD). The TPU nanocomposites are subjected to different measurements such as mechanical, thermal, hydrophobicity, flammability, water vapor, and oxygen barrier properties, as well as antimicrobial activity. The results showed that the major properties were improved when the nanoparticles were added, especially at 5 wt%. Furthermore, the TPU/CH blend reinforced with high contents of NPs (i.e., 5-7 wt%) exhibited efficient antimicrobial activities against Gram-negative, Gram-positive bacteria and, pathogenic fungi.

Preparation and characterization of starch-based nanocomposites reinforced by graphene oxide self-assembled on the surface of silanecouplingagent modified cellulose nanocrystals

The dispersion of cellulose nanocrystal (CNC) in starch matrix limited its application. In this study, CNC modified by silanecouplingagent before graphene oxide (GO) self-assembled on the surface of modified CNC, then CNC-GO as a filler was used to prepare starch-based nanocomposite films (CS/CNC-GO). The structure of CNC-GO and CS/CNC-GO films and the properties of CS/CNC-GO films were studied by FT-IR, Raman, SEM, surface potential, UV-Vis, moisture absorption and tensile tests. The results showed that GO was successfully self-assembled on the surface of CNC modified by silanecouplingagent. CNC-GO was superior to CNC in reinforcing the strength of starch film, improving the transmittance of starch film and decreasing moisture rate of starch film. Tensile strength, elongation at break and transmittance of CS/CNC-GO film with 5 wt% CNC-GO reached maximum, which was 53.96 MPa, 3.72% and 38.76%, respectively. Moisture rate of CS/CNC-GO film with 3 wt% CNC-GO reached minimum that was 12.13%. These were assigned to the more uniform dispersion of CNC-GO in the starch matrix and the stronger interfacial interaction between starch and CNC-GO.

Compatibilization of Starch/Synthetic Biodegradable Polymer Blends for Packaging Applications: A Review

The health and environmental concerns of the usage of non-biodegradable plastics have driven efforts to explore replacing them with renewable polymers. Although starch is a vital renewable polymer, poor water resistivity and thermo-mechanical properties have limited its applications. Recently, starch/synthetic biodegradable polymer blends have captured greater attention to replace inert plastic materials; the question of ‘immiscibility’ arises during the blend preparation due to the mixing of hydrophilic starch with hydrophobic polymers. The immiscibility issue between starch and synthetic polymers impacts the water absorption, thermo-mechanical properties, and chemical stability demanded by various engineering applications. Numerous studies have been carried out to eliminate the immiscibility issues of the different components in the polymer blends while enhancing the thermo-mechanical properties. Incorporating compatibilizers into the blend mixtures has significantly reduced the particle sizes of the dispersed phase while improving the interfacial adhesion between the starch and synthetic biodegradable polymer, leading to fine and homogeneous structures. Thus, Significant improvements in thermo-mechanical and barrier properties and water resistance can be observed in the compatibilized blends. This review provides an extensive discussion on the compatibilization processes of starch and petroleum-based polymer blends.

Continuous Blown Film Preparation of High Starch Content Composite Films with High Ultraviolet Aging Resistance and Excellent Mechanical Properties

Starch/PBAT blown films with high ultraviolet aging resistance and excellent mechanical properties were prepared by introducing lignin with polyurethane prepolymer (PUP) as a starch modifier and physical compatibilizer and 4,4'-methylene diphenyl diisocyanate (MDI) as a crosslinker. Starch was modified by reacting the NCO groups of the PUP with the OH groups of the starch to form a carbamate bond. The mechanical properties, hydrophobic properties, ultraviolet barrier, ultraviolet aging properties and microscopic morphology of starch/PBAT films with different contents of lignin were investigated. The results showed that the starch/PBAT films were blown continuously. The addition of lignin did not decrease the mechanical properties. On the contrary, the film with 1% lignin possessed the excellent mechanical properties with longitudinal tensile strength of 15.87 MPa and the elongation at a break of 602.21%. In addition, the higher the lignin content, the better the UV blocking effect. The introduction of lignin did not affect the crystalline properties but improved the hydrophilic properties and sealing strength of the high starch content composite films.

A comparative investigation of gelatinized and regenerated starch composites reinforced by microfibrillated cellulose

This research demonstrated a novel and ecofriendly method for producing regenerated starch (RS)/microfibrillated cellulose (MFC) composite films with a nearly 1.4-fold improvement in tensile strength than traditional gelatinized starch (GS) films. Pure starch was dissolved in 14 wt% urea/4 wt% sodium hydroxide (NaOH) solution at 0 °C. Then, RS films and their biocomposite films containing MFC were prepared by dialyzing and solution-casting method. Results showed that the tensile strength and elongation at break of RS increased by 44.8% and 82.4%, compared with that of GS film, respectively. Owing to the adequate dispersion, lower viscosity-average molecular weight, higher amylose content, lower crystallinity and smaller crystal grain size, RS/MFC composite films exhibited significantly improved mechanical properties. The novel strategy used in this study will be helpful in preparing regenerated starch materials with excellent mechanical properties and biodegradability as alternatives to petrochemical plastics for the development of sustainable materials.