Influence of extrusion process conditions on starch film morphology

The application of starch-based edible film in food preservation: a comprehensive review

Using renewable resources for food packaging not only helps reduce our dependence on fossil fuels but also minimizes the environmental impact associated with traditional plastics. Starch has been a hot topic in the field of current research because of its low cost, wide source and good film forming property. However, a comprehensive review in this field is still lacking. Starch-based films offer a promising alternative for sustainable packaging in the food industry. The present paper covers various aspects such as raw material sources, modification methods, and film formation mechanisms. Understanding the physicochemical properties and potential commercial applications is crucial for bridging the gap between research and practical implementation. Finally, the application of starch-based films in the food industry is discussed in detail. Different modifications of starch can improve the mechanical and barrier properties of the films. The addition of active substances to starch-based films can endow them with more functions. Therefore, these factors should be better investigated and optimized in future studies to improve the physicochemical properties and functionality of starch-based films. In summary, this review provides comprehensive information and the latest research progress of starch-based films in the food industry.

Effects of PVA and yerba mate extract on extruded films of carboxymethyl cassava starch/PVA blends for antioxidant and mechanically resistant food packaging

Global concerns over environmental damage caused by non-biodegradable single-use packaging have sparked interest in developing biomaterials. The food packaging industry is a major contributor to non-degradable plastic waste. This study investigates the impact of incorporating different concentrations of polyvinyl alcohol (PVA) and yerba mate extract as a natural antioxidant into carboxymethyl cassava starch films to possibly use as active degradable packaging to enhance food shelf life. Films with starch and PVA blends (SP) at different ratios (SP radios of 100:0, 90:10, 80:20 and 70:30) with and without yerba mate extract (Y) were successfully produced through extrusion and thermoforming. The incorporation of up to 20 wt% PVA improved starch extrusion processing and enhanced film transparency. PVA played a crucial role in improving the hydrophobicity, tensile strength and flexibility of the starch films but led to a slight deceleration in their degradation in compost. In contrast, yerba mate extract contributed to better compost degradation of the blend films. Additionally, it provided antioxidant activity, particularly in hydrophilic and lipophilic food simulants, suggesting its potential to extend the shelf life of food products. Starch-PVA blend films with yerba mate extract emerged as a promising alternative for mechanically resistant and active food packaging.

A review of starch-based biocomposites reinforced with plant fibers

Renewable and biodegradable resources have gained increasing attention as promising alternatives to synthetic plastics. Among the diverse raw materials employed in bioplastics production, starch emerges as an attractive, low-cost, and largely available source. However, the inherent properties of starch-based materials often limit their utility across various applications, necessitating strategic modifications to enhance their performance. A common approach to boost these materials involves incorporating natural fillers into biopolymer matrices. Incorporating natural fibers within starch matrices enables the development of biocomposites with improved properties while retaining their renewable and biodegradable characteristics. This review briefly addresses fundamental aspects of starch structure, obtention, and processing, as well as the main pre-treatments of natural fibers and processing methods currently applied to produce starch-based composites. It also highlights the most recent advances in this field, elucidates the effect of the incorporation of fibers on the biocomposite properties, and discusses the critical parameters affecting the synergic combination between starch and fibers.

Development of Antibacterial Thermoplastic Starch with Natural Oils and Extracts: Structural, Mechanical and Thermal Properties

In this study, the influence of the incorporation of eucalyptus (EO), tea tree (TT) and rosemary (RO) essential oils and Chiriyuyo extract (CE) on the structure and properties of thermoplastic starch (TPS) obtained from potato starch, glycerin and water was evaluated. All oils and the extract were used at a concentration of 0.5 g/100 g of TPS, while for TT, the effect of the concentration was also studied. The mixtures obtained were processed by extrusion and thermocompression molding. The sheets were characterized by XRD, FTIR, TGA, SEM and analyses of their mechanical properties, antimicrobial characteristics and biodegradability. The results show that the use of small concentrations of the oils in 70TPS does not induce changes in the TPS structure according to the results of XRD, FTIR and TGA, with each essential oil and CE affecting the mechanical properties unevenly, although in all cases, antimicrobial activity was obtained, and the biodegradability of TPS in soil was not modified. An increase in the concentration of TT in 60TPS causes marked changes in the crystallinity of TPS, providing a greater modulus with a higher concentration of TT. Regardless of the amount of TT, all sheets maintain antimicrobial characteristics, and their biodegradation in soil is delayed with a higher oil content.

Effect of Addition of Cross-Linked Starch on the Properties of Degraded PBAT Poly(butylene adipate-co-terephthalate) Films

This work aimed to evaluate the properties of butylene adipate-co-terephthalate (PBAT) degraded after 1800 days of storage (DPBAT) by preparing blends (films) with crosslinked starch (Cm) through extrusion and thermocompression. Different ratios of DPBAT:Cm (70:30, 60:40, and 50:50 m/m) were prepared. The incorporation of Cm into DPBAT significantly changed the properties of the films by making them stiffer (increasing Young's modulus by up to 50%) and increasing the thermal resistance of DPBAT. The presence of crosslinked starch in the films made them less hydrophobic (with decreased contact angle and increased moisture content), but these parameters did not vary linearly with changes in the content of crosslinked starch in the blend (DPBAT:Cm). The microscopic images show an inhomogeneous distribution of Cm granules in the DPBAT matrix. Thus, the films prepared with PBAT show a significant decrease in their mechanical parameters and heat resistance after long-term storage. However, the preparation of blends of degraded DPBAT with crosslinked starch promoted changes in the properties of the films prepared by thermocompression, which could be useful for disposable packaging.

A Review on Reinforcements and Additives in Starch-Based Composites for Food Packaging

The research of starch as a matrix material for manufacturing biodegradable films has been gaining popularity in recent years, indicating its potential and possible limitations. To compete with conventional petroleum-based plastics, an enhancement of their low resistance to water and limited mechanical properties is essential. This review aims to discuss the various types of nanofillers and additives that have been used in plasticized starch films including nanoclays (montmorillonite, halloysite, kaolinite, etc.), poly-saccharide nanofillers (cellulose, starch, chitin, and chitosan nanomaterials), metal oxides (titanium dioxide, zinc oxide, zirconium oxide, etc.), and essential oils (carvacrol, eugenol, cinnamic acid). These reinforcements are frequently used to enhance several physical characteristics including mechanical properties, thermal stability, moisture resistance, oxygen barrier capabilities, and biodegradation rate, providing antimicrobial and antioxidant properties. This paper will provide an overview of the development of starch-based nanocomposite films and coatings applied in food packaging systems through the application of reinforcements and additives.

Evolution of the free volume during water desorption in thermoplastic starch/citric acid films: In situ positron annihilation studies

The effect of citric acid (CA) concentration and water content on the free hole volume of thermoplastic cassava starch films (TPS) was studied. To this aim, continuous in situ positron annihilation lifetime spectroscopy measurements were performed at fixed moisture content and during water desorption. The results show that the increase in CA concentration leads to wider free hole volume distributions with lower mean values. During water desorption, the mean values and width of such distributions systematically decrease with the exposure time, and the evolution of the hole volumes was well-described using the Kohlrausch-Williams-Watts function. The water vapour permeability was significantly higher in films incorporating 5 % (w/w) of CA, in line with the more open network of this material that was revealed in the hole volumes distribution. The Young's modulus of all the developed films increased significantly after partial water desorption, which was attributed to the plasticizer loss reflected in a decrease in the mean hole volume value (between 4 % and 13 %). This work evidences that the control and report of the relative humidity are essential when testing TPS-based films, as their nanostructures are strongly dependent on external conditions.

Influence of acetylation and chemical interaction on edible film properties and different processing methods for food application

This study developed sweet potato starch (SPS) based edible films and investigated several methods (acetylation, amidated pectin (AP), and CaCl₂ use) to improve the edibility and different processing methods (casting and extruding) to package food possible in commercial use. Starch acetylation was conducted with up to 8 mL of acetic acid (A8) and improved the stretchability and solubility of the film. The AP addition [∼30 wt% (P3)] enhanced the film strength, further increasing solubility. CaCl₂ addition [∼150 mg/g of AP (C3)] also positively influenced the film solubility and water barrier properties of the films. The SPS-A8P3C3 film showed 3.41 times higher solubility than the native SPS film. Both casted and extruded SPS-A8P3C3 films drastically dissolved in high-temperature water. When applied to oil packaging, two films could delay the lipid oxidation of the packaged samples. These results demonstrate the usability of edible packaging and extruded film for commercial use.

Co-Plasticization of Starch with Glycerol and Isosorbide: Effect on Retrogradation in Thermo-Plastic Cassava Starch Films

Thermoplastic starch (TPS) has emerged as an essential alternative to produce environmentally friendly packaging; however, retrogradation is a disadvantage that affects its shelf life. This study analyzed the co-plasticizing effect of isosorbide on the mechanical, thermal, physicochemical, and microstructural properties and the retrogradation of films obtained by blown film extrusion from thermoplasticized starch with mixtures of glycerol and isosorbide in different ratios (3:0, 2:1, 1:2, and 0:3, respectively). The results showed that the higher concentration of isosorbide significantly increased the tensile strength; however, it reduced the elongation. Retrogradation modeled using the Avrami equation showed that the presence of isosorbide reduced the retrogradation rate (k) and modified the recrystallization mechanism (n). The relative crystallinity in the plasticized TPS films was reduced to 89%, and the adsorption significantly decreased. Isosorbide was very important in reducing the retrogradation of TPS. The best performance was obtained with the 2:1 ratio of glycerol/isosorbide due to the synergistic effect between the plasticizers. The results would allow tuning the properties of TPS films by combining glycerol/isosorbide in different ratios, which enables the design of materials tailored to potential application requirements.

Potato thermoplastic starch nanocomposite films reinforced with nanocellulose

Potato is a widely available feedstock with biocompatibility and biodegradability properties, making it a strong candidate for producing thermoplastic starch. The application of thermoplastic starch to replace petroleum-based plastic as a sustainable and environmentally friendly approach led to its further improvement through various techniques such as modification and filler reinforcement. Numerous studies have been done addressing the properties enhancement of potato thermoplastic starch through filler reinforcement including nanocellulose. This review focus on the recent and future potential of potato-based starch as one of the feedstocks for producing potato thermoplastic starch composites reinforced with nanocellulose.

Bio-nanocomposites films based on unmodified and modified thermoplastic starch reinforced with chemically modified nanoclays

The use of polymers capable of being degraded by the action of microorganisms and/or enzymes without causing harmful effects is a strategy in waste management and environmental care. In this work, bio-nanocomposites based on thermoplastic starch (TPS) were synthesized by reactive extrusion using a twin-screw extruder. Two strategies were evaluated to reduce the disadvantages of TPS for packaging applications. First, starch was chemically modified producing the reaction of native starch with chemical reagents that introduce new functional groups to reduce the water adsorption. And two, nano-fillers were incorporated into TPS in order to enhance the mechanical and barrier properties, driving to materials with improved performance/cost ratio. The synergistic strategies of chemical modification and incorporation of modified nanoclays were also effective to reduce the dependence of properties of TPS with the environment humidity and the evolution thereof over time, which influences the performance during the service life of the product.

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s10853-023-08354-1.

Recent progress in pectin extraction and their applications in developing films and coatings for sustainable food packaging: A review

Perishable foods like fruits and vegetables, meat, fish, and dairy products have short shelf-life that causes significant postharvest losses, which poses a major challenge for food supply chains. Biopolymers have been extensively studied as sustainable alternatives to synthetic plastics, and pectin is one such biopolymer that has been used for packaging and preservation of foods. Pectin is obtained from abundantly available low-cost sources such as agricultural or food processing wastes and by products. This review is a complete account of pectin extraction from agro-wastes, development of pectin-based composite films and coatings, their characterizations, and their applications in food packaging and preservation. Compared to conventional chemical extraction, supercritical water, ultrasound, and microwave assisted extractions are a few examples of modern and more efficient pectin extraction processes that generate almost no hazardous effluents, and thus, such extraction techniques are more environment friendly. Pectin-based films and coatings can be functionalized with natural active agents such as essential oils and other phytochemicals to improve their moisture barrier, antimicrobial and antioxidant properties. Application of pectin-based active films and coatings effectively improved shelf-life of fresh cut-fruits, vegetables, meat, fish, poultry, milk, and other food perishable products.

Effect of TiO2 Nanoparticles and Extrusion Process on the Physicochemical Properties of Biodegradable and Active Cassava Starch Nanocomposites

Biodegradable polymers have been strongly recognized as an alternative to replace traditional petrochemical plastics, which have become a global problem due to their long persistence in the environment. In this work, the effect of the addition of titanium dioxide nanoparticles (TiO₂NP) on the morphology, physicochemical properties and biodegradation under industrial composting conditions of cassava starch-based nanocomposites obtained by extrusion at different screw speeds (80 and 120 rpm) were investigated. Films performed at 120 rpm (S₁₂₀ and S₁₂₀-TiO₂NP) showed completely processed starch and homogeneously distributed nanoparticles, leading to much more flexible nanocomposites than those obtained at 80 rpm. The incorporation of TiO₂NP led to an increase in storage modulus of all films and, in the case of S₁₂₀-TiO₂NP, to higher strain at break values. From the Kohlrausch-Williams-Watts theoretical model (KWW), an increase in the relaxation time of the nanocomposites was observed due to a decrease in the number of polymer chains involved in the relaxation process. Additionally, S₁₂₀-TiO₂NP showed effective protection against UV light, greater hydrophobicity and faster biodegradation in compost, resulting in a promising material for food packaging applications.

Effect of new type extrusion modification technology on supramolecular structure and in vitro glycemic release characteristics of starches with various estimated glycemic indices

Nowadays, the highly effective modified technology to starch with various digestibility is gaining interest in food science. Here, the interactions between glycemic release characteristics and fine supramolecular structure of cassava (ECS), potato (EPS), jackfruit seed (EJFSS), maize (EMS), wheat (EWS), and rice starches (ERS) prepared with improved extrusion modification technology (IEMS) were investigated. The crystalline structures of all extruded cooking starches changed from the A-type to V-type. IEMS-treated cassava, potato, and rice starches had broken α-1.6-glycosidic amylopectin (long chains). The others sheared α-1.4-glycosidic amylopectin. The molecular weight, medium and long chain counts, and relative crystallinity decreased, whereas the number of amylopectin short chains increased. The glycemic index (GI) and digestive speed rate constant (k) of ECS, EPS, EJFSS, and EWS were improved compared to those of raw starch. Although EMS and ERS had degraded molecular structures, their particle morphology changed from looser polyhedral to more compact with less enzymolysis channels due to the rearrangement of side chain clusters of amylopectin, leading to enzyme resistance. The starch characteristics of IEMS-treated samples significantly differed. EPS had the highest amylose content, medium chains, long chains, and molecular weight but lowest GI, relative crystallinity, and k. ERS showed the opposite results. Thus, IEMS may affect starches with different GIs to varying degrees. In this investigation, we provide a basis for wider applications of conventional crop starch in the food industry corresponding to different nutrition audience.

Progress in Starch-Based Materials for Food Packaging Applications

The food packaging sector generates large volumes of plastic waste due to the high demand for packaged products with a short shelf-life. Biopolymers such as starch-based materials are a promising alternative to non-renewable resins, offering a sustainable and environmentally friendly food packaging alternative for single-use products. This article provides a chronology of the development of starch-based materials for food packaging. Particular emphasis is placed on the challenges faced in processing these materials using conventional processing techniques for thermoplastics and other emerging techniques such as electrospinning and 3D printing. The improvement of the performance of starch-based materials by blending with other biopolymers, use of micro- and nano-sized reinforcements, and chemical modification of starch is discussed. Finally, an overview of recent developments of these materials in smart food packaging is given.

Functionality and Applicability of Starch-Based Films: An Eco-Friendly Approach

The accumulation of high amounts of petro-based plastics is a growing environmental devastation issue, leading to the urgent need to innovate eco-safe packaging materials at an equivalent cost to save the environment. Among different substitutes, starch-based types and their blends with biopolymers are considered an innovative and smart material alternative for petrol-based polymers because of their abundance, low cost, biodegradability, high biocompatibility, and better-quality film-forming and improved mechanical characteristics. Furthermore, starch is a valuable, sustainable food packaging material. The rising and growing importance of designing starch-based films from various sources for sustainable food packaging purposes is ongoing research. Research on "starch food packaging" is still at the beginning, based on the few studies published in the last decade in Web of Science. Additionally, the functionality of starch-based biodegradable substances is technically a challenge. It can be improved by starch modification, blending starch with other biopolymers or additives, and using novel preparation techniques. Starch-based films have been applied to packaging various foods, such as fruits and vegetables, bakery goods, and meat, indicating good prospects for commercial utilization. The current review will give a critical snapshot of starch-based films' properties and potential applicability in the sustainable smart (active and intelligent) new packaging concepts and discuss new challenges and opportunities for starch bio composites.

Essential oils as additives in active starch-based food packaging films: A review

The production of sustainable food packaging from renewable sources represents a prominent alternative to the use of petrochemical-based plastics. For example, starch remains one of the more closely studied replacement options due to its broad availability, low cost and significant advances in improving properties. In this context, essential oils as additives fulfil a key role in the manufacture of renewable active packaging with superior performances. In this review, a comprehensive summary of the impact of adding essential oils to the starch-based films is provided. After a brief introduction to the fundamental concepts related to starch and essential oils, details on the most recent advances in obtaining active starch-based films are presented. Subsequently, the effects of essential oils addition on the structure-property relationships (from physicochemical to antimicrobial ones) are thoroughly addressed. Finally, applications and challenges to the widespread use of essential oils are critically discussed.

Approaches in Animal Proteins and Natural Polysaccharides Application for Food Packaging: Edible Film Production and Quality Estimation

Natural biopolymers are an interesting resource for edible films production, as they are environmentally friendly packaging materials. The possibilities of the application of main animal proteins and natural polysaccharides are considered in the review, including the sources, structure, and limitations of usage. The main ways for overcoming the limitations caused by the physico-chemical properties of biopolymers are also discussed, including composites approaches, plasticizers, and the addition of crosslinking agents. Approaches for the production of biopolymer-based films and coatings are classified according to wet and dried processes and considered depending on biopolymer types. The methods for mechanical, physico-chemical, hydration, and uniformity estimation of edible films are reviewed.

Effect of greenly synthetized silver nanoparticles on the properties of active starch films obtained by extrusion and compression molding

Replacing packaging plastics with biodegradable active materials is an emerging concern. In this context, thermoplastic starch (TPS) films and nanocomposites containing different concentrations of silver nanoparticles synthetized with starch and yerba mate (TPS-AgNP₁: 0.006 wt.% and TPS-AgNP₂: 0.015 wt.%) were developed by extrusion and compression molding. Spherical AgNP of 20-130 nm were obtained after the green synthesis and excellent adhesion between AgNP and the matrix was observed. Consequently, both composites exhibited higher stiffness and tensile strength values than TPS, indicating a reinforcing effect of AgNP. TPS-AgNP₁ showed the highest strain at break and toughness values, and TPS-AgNP₂ presented the lowest moisture content and ability to delay E. coli growth. Additionally, all materials disintegrated after 4 weeks of burial and resulted thermally stable up to 240 °C. This investigation provides a convenient and inexpensive way to develop starch-based nanocomposites with improved properties which appear to be promising as active packaging materials.

Fortification of edible films with bioactive agents: a review of their formation, properties, and application in food preservation

Biodegradable films constructed from food ingredients are being developed for food coating and packaging applications to create more sustainable and environmentally friendly alternatives to plastics and other synthetic film-forming materials. In particular, there is a focus on the creation of active packaging materials from natural ingredients, especially plant-based ones. The film matrix is typically constructed from film-forming food components, such as proteins, polysaccharides and lipids. These matrices can be fortified with active ingredients, such as antioxidants and antimicrobials, so as to enhance their functional properties. Edible active films must be carefully designed to have the required optical, mechanical, barrier, and preservative properties needed for commercial applications. This review focuses on the fabrication, properties, and functional performance of edible films constructed from natural active ingredients. It provides an overview of the type of active ingredients that can be used, how they interact with the film matrix, how they migrate through the films, and how they are released. It also discusses the potential application of these active films for food preservation. Finally, future trends are highlighted and areas where further research are required are discussed.

Supramolecular structure of Artocarpus heterophyllus Lam seed starch prepared by improved extrusion cooking technology and its relationship with in vitro digestibility

Jackfruit seed starch (JFSS) was modified by an improved extrusion cooking technology (IECT), and the supramolecular structure, molecular weight, debranched chain length distributions, relative crystallinity (Rc), and amylose content, were studied. During IECT, the α-1.4-glycosidic bond in amylopectin was broken, which led to decreased radius of gyration (Rg), number-average molar mass (Mn), weight-average molar mass (Mw), long chains and Rc. The medium and short chains and PI (Mw/Mn) increased, while the amylose content hardly changed. The crystalline structure of JFSS was converted from A-type to V-type. Increasing the temperature and screw speed during the treatment significantly increased the medium and short chains and Rg, while it decreased the long chains, amylose, Mn, Mw, PI, and Rc. However, the opposite effect was observed when increasing the moisture content. The in vitro digestibility of JFSS was significantly improved after IECT, due to destruction of starch supramolecular structure according to principal component analysis.

Effect of yerba mate extract on the performance of starch films obtained by extrusion and compression molding as active and smart packaging

Native or hydrolyzed starch and yerba mate extract (10 wt.% or 20 wt.%) films prepared by extrusion and compression molding were investigated. Native starch material (TPNS) exhibited lower water vapor permeability and higher Young's Modulus (E) compared to hydrolyzed starch matrix (TPHS) but decreases in strain at break (ε_b) and toughness (T). The incorporation of 10 wt.% of extract in TPNS led to greater E and ε_b and it resulted the most hydrophobic material. Conversely, TPHS with 20 wt.% of additive resulted the film with the highest ε_b and T, indicating a plasticizing effect of the extract in this concentration and system. All materials disintegrated after 10 weeks of burial, contributing to waste reduction. Biofilms containing yerba mate extract showed antioxidant activity and color changes in different pH, indicating their promising role as active and smart packaging for food, in accordance with the new trends for biodegradable and functional packaging.

Characterization of Starches Isolated from Colombian Native Potatoes and Their Application as Novel Edible Coatings for Wild Andean Blueberries (Vaccinium meridionale Swartz)

Andean blueberry is a promissory fruit native to South America. The current work aimed to characterize starches isolated from Colombian native potatoes and to evaluate the effect of the application of starch edible coatings on the changes in the physicochemical quality parameters of the Andean blueberry during storage. Starches were isolated from three different potatoes varieties (pacha negra, mora, and alcarrosa) and characterized. Then, starch-based coatings were applied to Andean blueberries, and the changes in their quality parameters were monitored during 12 days of storage. Despite the phenotypical differences in the starch sources used, starches were similar in terms of their granule morphology, amylose content (~19%), crystallinity degree (~46%), and thermal properties. Coatings were able to reduce the gaseous exchange of the fruit, and, thus, the respiration rate of all coated blueberries was ~27% lower compared to the uncoated fruits (p < 0.05) at the end of the storage. While the application of starch coatings did not prevent water loss, all samples reached water loss of up 20%. Besides, the coated fruits showed soluble solids contents ~14% higher compared to the control one, as well as better bright and firmness. The new edible coatings can help add value to the Andean blueberry.

Optimization of corn starch acetylation and succinylation using the extrusion process

Starch chemical modification can be used in order to obtain modified starches (MS) with low affinity to water. Acetylated and succinylated starches whose applications as food ingredient depend upon their degree of substitution (DS) may be produced by esterifying starch through the extrusion process (EP). The Food and Drug Administration recommends a DS of 0.2 and 0.05 for acetylated and succinylated starches, respectively. The objective of this study was to find mathematical models to obtain the optimum values of DS, Water absorption Index (WAI) and Water Solubility Index (WSI) for MS with safe-for-food-use DS and low affinity to water, modifying the starches by acetylation and succinylation using EP. The process variables were Barrel Temperature (BT, 80-160 °C), Screw Speed (SS, 100-200 rpm) and Reactant Concentration (RC, Acetylation, 0-13% and Succinylation, 0-3%). The best conditions to obtain acetylated starches were RC = 7.88%, BT = 80 °C and SS = 100 rpm, presenting values of DS = 0.2, WAI = 7.67 g/g and WSI = 6.15%. On the other hand, the optimum conditions to obtain succinylated starches were RC = 1.12%, BT = 80 °C and SS = 126 rpm, obtaining values of DS = 0.05, WAI = 3.40 g/g and WSI = 7.92%. These results showed that it is possible to obtain acetylated and succinylated MS with safe-for-food-use levels of DS and with low affinity to water, using EP.