Physical explanations about the improvement of PolyHydroxyButyrate ductility: Hidden effect of plasticizer on physical ageing

Innovative biomaterials for food packaging: Unlocking the potential of polyhydroxyalkanoate (PHA) biopolymers

Polyhydroxyalkanoate (PHA) biopolyesters show a good balance between sustainability and performance, making them a competitive alternative to conventional plastics for ecofriendly food packaging. With an emphasis on developments over the last decade (2014-2024), this review examines the revolutionary potential of PHAs as a sustainable food packaging material option. It also delves into the current state of commercial development, competitiveness, and the carbon footprint associated with PHA-based products. First, a critical examination of the challenges experienced by PHAs in terms of food packaging requirements is undertaken, followed by an assessment of contemporary strategies addressing permeability, mechanical properties, and processing considerations. The various PHA packaging end-of-life options, including a comprehensive overview of the environmental impact and potential solutions will also be discussed. Finally, conclusions and future perspectives are elucidated with a view of prospecting PHAs as future green materials, with a blend of performance and sustainability of food packaging solutions.

Recycling and 3D-Printing Biodegradable Membranes for Gas Separation-toward a Membrane Circular Economy

Polymer membranes employed in gas separation play a pivotal role in advancing environmental sustainability, energy production, and gas purification technologies. Despite their significance, the current design and manufacturing of these membranes lack cradle-to-cradle approaches, contributing to plastic waste pollution. This study explores emerging solutions, including the use of biodegradable biopolymers such as polyhydroxybutyrate (PHB) and membrane recycling, with a focus on the specific impact of mechanical recycling on the performance of biodegradable gas separation membranes. This research represents the first systematic exploration of recycling biodegradable membranes for gas separation. Demonstrating that PHB membranes can be recycled and remanufactured without solvents using hot-melt extrusion and 3D printing, the research highlights PHB's promising performance in developing more sustainable CO2 separations, despite an increase in gas permeability with successive recycling steps due to reduced polymer molecular weight. The study emphasizes the excellent thermal, chemical, and mechanical stability of PHB membranes, albeit with a marginal reduction in gas selectivity upon recycling. However, limitations in PHB's molecular weight affecting extrudability and processability restrict the recycling to three cycles. Anticipating that this study will serve as a foundational exploration, we foresee more sophisticated recycling studies for gas separation membranes, paving the way for a circular economy in future membrane technologies.

PHB+aPHA Blends: From Polymer Bacterial Synthesis through Blend Preparation to Final Processing by Extrusion for Sustainable Materials Design

The inherent brittleness of polyhydroxybutyrate (PHB), a well-studied polyhydroxyalkanoate (PHA), limits its applicability in flexible and impact-resistant applications. This study explores the potential of blending PHB with a different PHA to overcome brittleness. The synthesis of PHA polymers, including PHB and an amorphous medium-chain-length PHA (aPHA) consisting of various monomers, was achieved in previous works through canola oil fermentation. Detailed characterization of aPHA revealed its amorphous nature, as well as good thermal stability and shear thinning behavior. The blending process was carried out at different mass ratios of aPHA and PHB, and the resulting blends were studied by differential scanning calorimetry (DSC), X-ray diffraction (XRD), scanning electron microscopy (SEM), and thermogravimetric analysis (TGA). The blends exhibited complex DSC curves, indicating the presence of multiple crystalline forms of PHB. SEM images revealed the morphology of the blends, with PHB particles dispersed within the aPHA matrix. TGA showed similar thermal degradation patterns for the blends, with the residue content decreasing as the PHB content increased. The crystallinity of the blends was influenced by the PHB content, with higher PHB ratios resulting in an increased degree of crystallinity. XRD confirmed the presence of both α and β crystals of PHB in the blends. Overall, the results demonstrate the potential of PHB+aPHA blends to enhance the mechanical properties of biopolymer materials, without com-promising the thermal stability, paving the way for sustainable material design and novel application areas.

The effects of PHB-g-MA types on the mechanical, thermal, morphological, structural, and rheological properties of polyhydroxybutyrate biopolymers

This study investigates the grafting of polyhydroxybutyrate (PHB) chains with maleic anhydride (MA) in concentrations ranging from 5 % to 10 % by weight. This process was conducted during microwave treatment and using a reactive extruder, employing benzoyl peroxide (BPO) as the initiator. The impact of these methods on PHB's overall properties was thoroughly investigated. In the study, PHB-g-MA was incorporated into neat PHB via the extrusion process at a 5 % loading rate. Notably, the mechanical properties exhibited an increase in the presence of PHB-g-MA, likely due to morphological improvements in the neat PHB, as indicated by morphological characterization. X-ray diffraction results indicated crystallinity percentages increase with the addition of MA. Differential scanning calorimetry revealed minimal variation in melting and crystallization temperatures when PHB-g-MA was included. Both storage and loss moduli were enhanced by the incorporation of PHB-g-MA, and the blends exhibited consistent tan delta values. Regarding rheological properties, the storage and loss moduli of PHB blends containing PHB-g-MA blends were observed to rise with rising frequency values. Based on these results, the microwave process was identified as the most effective method for grafting.

Effect of oligomeric lactic acid plasticizer on the mechanical recycling of poly(3-hydroxybutyrate-co-3-hydroxyvalerate)

Bioplastics such as polyhydroxyalkanoates (PHA) emerge as an interesting alternative to conventional fossil fuel-based plastics and as part of the solution their associated environmental issues. Nevertheless, end-of-life scenarios are still a major concern, especially within a circular economy framework. When feasible, mechanical recycling appears as the best alternative, since it saves raw materials and energy. However, the viability of mechanical recycling can be compromised by the degradation of the plastic during its use and during the recycling process and by the presence of certain additives. Consequently, the main objective of this work is to study the effect of accelerated ageing and mechanical recycling on the structure and properties of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV)-based formulations. The obtained results suggest that accelerated ageing and mechanical recycling led only to a slight degradation of the pure PHBV material, along with small variations in the thermal and mechanical properties. However, the plasticized PHBV formulations showed a more severe degradation and increased thermal stability and stiffness, which could be result of the elimination of the plasticizer during the recycling. Overall, mechanical recycling seems to be an interesting valorization strategy for PHBV wastes, although especial attention should be paid to the additives present in the materials.

Characterization of Poly(3-hydroxybutyrate) (P3HB) from Alternative, Scalable (Waste) Feedstocks

Bioplastics hold significant promise in replacing conventional plastic materials, linked to various serious issues such as fossil resource consumption, microplastic formation, non-degradability, and limited end-of-life options. Among bioplastics, polyhydroxyalkanoates (PHA) emerge as an intriguing class, with poly(3-hydroxybutyrate) (P3HB) being the most utilized. The extensive application of P3HB encounters a challenge due to its high production costs, prompting the investigation of sustainable alternatives, including the utilization of waste and new production routes involving CO2 and CH4. This study provides a valuable comparison of two P3HBs synthesized through distinct routes: one via cyanobacteria (Synechocystis sp. PCC 6714) for photoautotrophic production and the other via methanotrophic bacteria (Methylocystis sp. GB 25) for chemoautotrophic growth. This research evaluates the thermal and mechanical properties, including the aging effect over 21 days, demonstrating that both P3HBs are comparable, exhibiting physical properties similar to standard P3HBs. The results highlight the promising potential of P3HBs obtained through alternative routes as biomaterials, thereby contributing to the transition toward more sustainable alternatives to fossil polymers.

Polyhydroxybutyrate blends: A solution for biodegradable packaging?

Poly (3-hydroxybutyrate) (PHB) is a valuable bio-based and biodegradable polymer that may substitute common polymers in packaging and biomedical applications provided that the production cost is reduced and some properties improved. Blending PHB with other biodegradable polymers is the most simple and accessible route to reduce costs and to improve properties. This review provides a comprehensive overview on the preparation, properties and application of the PHB blends with other biodegradable polyesters such as medium-chain-length polyhydroxyalkanoates, poly(ε-caprolactone), poly(lactic acid), poly(butylene succinate), poly(propylene carbonate) and poly (butylene adipate-co-terephthalate) or polysaccharides and their derivatives. A special attention has been paid to the miscibility of PHB with these polymers and the compatibilizing methods used to improve the dispersion and interface. The changes in the PHB morphology, thermal, mechanical and barrier properties induced by the second polymer have been critically analyzed in view of industrial application. The biodegradability and recyclability strategies of the PHB blends were summarized along with the processing techniques adapted to the intended application. This review provides the tools for a better understanding of the relation between the micro/nanostructure of PHB blends and their properties for the further development of PHB blends as solutions for biodegradable packaging.

Plasticization of Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) with an Oligomeric Polyester: Miscibility and Effect of the Microstructure and Plasticizer Distribution on Thermal and Mechanical Properties

In the last few decades, many efforts have been made to make poly(3-hydroxybutyrate) (PHB) and its copolymers more suitable for industrial production and large-scale use. Plasticization, especially using biodegradable oligomeric plasticizers, has been one of the strategies for this purpose. However, PHB and its copolymers generally present low miscibility with plasticizers. An understanding of the plasticizer distribution between the mobile and rigid amorphous phases and how this influences thermal, mechanical, and morphological properties remains a challenge. Herein, formulations of poly(hydroxybutyrate-co-valerate) (PHBV) plasticized with an oligomeric polyester based on lactic acid, adipic acid, and 1,2-propanediol (PLAP) were prepared by melt extrusion. The effects of the PLAP content on the processability, miscibility, and microstructure of the semicrystalline PHBV and on the thermal, morphological, and mechanical properties of the formulations were investigated. The compositions of the mobile and rigid amorphous phases of the PHBV/PLAP formulations were easily estimated by combining dynamic mechanical data and the Fox equation, which showed a heterogeneous distribution of PLAP in these two phases. An increase in the PLAP mass fraction in the formulations led to progressive changes in the composition of the amorphous phases, an increase of both crystalline lamellae and interlamellar layer thickness, and a decrease in the melting and glass transition temperatures as well as the PHBV stiffness. The Flory-Huggins interaction parameter varied with the formulation composition in the range of -0.299 to -0.081. The critical PLAP mass fraction of 0.37 obtained from thermodynamic data is close to the value estimated from dynamic mechanical analysis (DMA) data and the Fox equation. The mechanical properties showed a close relationship with the distribution of PLAP in the rigid and mobile amorphous phases as well as with the microstructure of the crystalline phase of PHBV in the formulations.

In vivo and Post-synthesis Strategies to Enhance the Properties of PHB-Based Materials: A Review

The transition toward "green" alternatives to petroleum-based plastics is driven by the need for "drop-in" replacement materials able to combine characteristics of existing plastics with biodegradability and renewability features. Promising alternatives are the polyhydroxyalkanoates (PHAs), microbial biodegradable polyesters produced by a wide range of microorganisms as carbon, energy, and redox storage material, displaying properties very close to fossil-fuel-derived polyolefins. Among PHAs, polyhydroxybutyrate (PHB) is by far the most well-studied polymer. PHB is a thermoplastic polyester, with very narrow processability window, due to very low resistance to thermal degradation. Since the melting temperature of PHB is around 170-180°C, the processing temperature should be at least 180-190°C. The thermal degradation of PHB at these temperatures proceeds very quickly, causing a rapid decrease in its molecular weight. Moreover, due to its high crystallinity, PHB is stiff and brittle resulting in very poor mechanical properties with low extension at break, which limits its range of application. A further limit to the effective exploitation of these polymers is related to their production costs, which is mostly affected by the costs of the starting feedstocks. Since the first identification of PHB, researchers have faced these issues, and several strategies to improve the processability and reduce brittleness of this polymer have been developed. These approaches range from the in vivo synthesis of PHA copolymers, to the enhancement of post-synthesis PHB-based material performances, thus the addition of additives and plasticizers, acting on the crystallization process as well as on polymer glass transition temperature. In addition, reactive polymer blending with other bio-based polymers represents a versatile approach to modulate polymer properties while preserving its biodegradability. This review examines the state of the art of PHA processing, shedding light on the green and cost-effective tailored strategies aimed at modulating and optimizing polymer performances. Pioneering examples in this field will be examined, and prospects and challenges for their exploitation will be presented. Furthermore, since the establishment of a PHA-based industry passes through the designing of cost-competitive production processes, this review will inspect reported examples assessing this economic aspect, examining the most recent progresses toward process sustainability.

Study of the Compatibilization Effect of Different Reactive Agents in PHB/Natural Fiber-Based Composites

Fiber–matrix interfacial adhesion is one of the key factors governing the final properties of natural fiber-based polymer composites. In this work, four extrusion reactive agents were tested as potential compatibilizers in polyhydroxylbutyrate (PHB)/cellulose composites: dicumyl peroxide (DCP), hexamethylene diisocyanate (HMDI), resorcinol diglycidyl ether (RDGE), and triglycidyl isocyanurate (TGIC). The influence of the fibers and the different reactive agents on the mechanical properties, physical aging, and crystallization behavior were assessed. To evaluate the compatibilization effectiveness of each reactive agent, highly purified commercial cellulose fibers (TC90) were used as reference filler. Then, the influence of fiber purity on the compatibilization effect of the reactive agent HMDI was evaluated using untreated (U_RH) and chemically purified (T_RH) rice husk fibers, comparing the results with the ones using TC90 fibers. The results show that reactive agents interact with the polymer matrix at different levels, but all compositions showed a drastic embrittlement due to the aging of PHB. No clear compatibilization effect was found using DCP, RDGE, or TGIC reactive agents. On the other hand, the fiber–polymer interfacial adhesion was enhanced with HMDI. The purity of the fiber played an important role in the effectiveness of HMDI as a compatibilizer, since composites with highly purified fibers showed the greatest improvements in tensile strength and the most favorable morphology. None of the reactive agents negatively affected the compostability of PHB. Finally, thermoformed trays with good mold reproducibility were successfully obtained for PHB/T_RH/HMDI composition.

Active biodegradable packaging films modified with grape seeds lignin

Biodegradable packaging materials represent one possible solution for how to reduce the negative environmental impact of plastics. The main idea of this work was to investigate the possibility of utilizing grape seed lignin for the modification of polyhydroxyalkanoates with the use of its antioxidant capacity in packaging films. For this purpose, polymeric films based on the blend of high crystalline poly(3-hydroxybutyrate) (PHB) and amorphous polyhydroxyalkanoate (PHA) were prepared. PHB/PHA films displayed Young modulus of 240 MPa, tensile strength at a maximum of 6.6 MPa and elongation at break of 95.2%. The physical properties of PHB/PHA films were modified by the addition of 1-10 wt% of grape seeds lignin (GS-L). GS-L lignin showed a high antioxidant capacity: 238 milligrams of Trolox equivalents were equal to one gram of grape seeds lignin. The incorporation of grape seeds lignin into PHB/PHA films positively influenced their gas barrier properties, antioxidant activity and biodegradability. The values of oxygen and carbon dioxide transition rate of PHB/PHA with 1 wt% of GS-L were 7.3 and 36.3 cm3 m-2 24 h 0.1 MPa, respectively. The inhibition percentage of the ABTS radical determined in PHB/PHA/GS-L was in the range of 29.2% to 100% depending on the lignin concentration. The biodegradability test carried out under controlled composting environment for 90 days showed that the PHB/PHA film with 50 w/w% of amorphous PHA reached the degradability degree of 68.8% being about 26.6% higher decomposition than in the case of neat high crystalline PHB film. The degradability degree of PHA films in compost within the tested period reflected the modification of the semi-crystalline character and varied with the incorporated lignin. From the toxicological point of view, the composts obtained after biodegradation of PHA films proved the non-toxicity of PHB/PHA/GS-L materials and its degradation products showed a positive effect on white mustard (Sinapis alba L.) seeds germination.

Binary polyhydroxyalkanoate systems for soft tissue engineering

Progress in tissue engineering is dependent on the availability of suitable biomaterials. In an effort to overcome the brittleness of poly(3-hydroxybutyrate), P(3HB), a natural biodegradable polyester, and widen its biomedical applications, plasticising of P(3HB) with oligomeric substances of related structure has been studied. A biosynthesised medium-chain-length polyhydroxyalkanoate (mcl-PHA) copolymer, the plasticiser precursor, was obtained using vegetable waste frying oil as a sole carbon source. The mcl-PHA was transformed into an oligomeric derivative by acid hydrolysis. The plasticising effect of the oligomeric mcl-PHA on P(3HB) was studied via characterisation of thermal and mechanical properties of the blends in the course of ageing at ambient conditions. Addition of oligomeric mcl-PHA to P(3HB) resulted in softer and more flexible materials based entirely on PHAs. It was shown that the oligomeric mcl-PHA transformed highly crystalline P(3HB) into materials with a dominant amorphous phase when the content of oligomeric mcl-PHA exceeded 10 wt%. In vitro biocompatibility studies of the new binary PHA materials showed high viability and proliferation of C2C12 myoblast cells. Thus, the proposed approach for P(3HB) plasticisation has the potential for the generation of more pliable biomaterials based on P(3HB) which can find application in unique soft tissue engineering applications where a balance between stiffness, tensile strength and ductility is required.

STATEMENT OF SIGNIFICANCE

Polyhydroxyalkanoates, a broad family of natural biodegradable and biocompatible polymers, have emerged as highly promising biomaterials both for bulk and biomedical applications. Here we describe an approach to tune the mechanical properties of stiff and brittle poly(3-hydroxybutyrate) and thereby to expand its potential biomedical applications. Plasticisation, a common practice in the plastic industry to modify polymer mechanical properties, has been used very cautiously for biomedical applications due to plasticiser toxicity and migration. We have developed a plasticiser for poly(3-hydroxybutyrate) based on a structurally related but softer and pliable medium chain length polyhydroxyalkanoate. Additives of oligomeric derivatives of this polymer improved ductility of poly(3-hydroxybutyrate), greatly widening the future applicability of this well-established biomaterial. In parallel, the binary polyhydroxyalkanoate materials also exhibited improved cell attachment and proliferation, a highly desirable outcome.