Sustainable production of cellulosic biopolymers for enhanced smart food packaging: An up-to-date review

Biodegradable and sustainable food packaging (FP) materials have gained immense global importance to reduce plastic pollution and environmental impact. Therefore, this review focused on the recent advances in biopolymers based on cellulose derivatives for FP applications. Cellulose, an abundant and renewable biopolymer, and its various derivatives, namely cellulose acetate, cellulose sulphate, nanocellulose, carboxymethyl cellulose, and methylcellulose, are explored as promising substitutes for conventional plastic in FP. These reviews focused on the production, modification processes, and properties of cellulose derivatives and highlighted their potential for their application in FP. Finally, we reviewed the effects of incorporating cellulose derivatives into film in various aspects of packaging properties, including barrier, mechanical, thermal, preservation aspects, antimicrobial, and antioxidant properties. Overall, the findings suggest that cellulose derivatives have the potential to replace conventional plastics in food packaging applications. This can contribute to reducing plastic pollution and lessening the environmental impact of food packaging materials. The review likely provides insights into the current state of research and development in this field and underscores the significance of sustainable food packaging solutions.

Enhancing Mechanical and Antimicrobial Properties of Dialdehyde Cellulose-Silver Nanoparticle Composites through Ammoniated Nanocellulose Modification

Given the widespread prevalence of viruses, there is an escalating demand for antimicrobial composites. Although the composite of dialdehyde cellulose and silver nanoparticles (DAC@Ag1) exhibits excellent antibacterial properties, its weak mechanical characteristics hinder its practical applicability. To address this limitation, cellulose nanofibers (CNFs) were initially ammoniated to yield N-CNF, which was subsequently incorporated into DAC@Ag1 as an enhancer, forming DAC@Ag1/N-CNF. We systematically investigated the optimal amount of N-CNF and characterized the DAC@Ag1/N-CNF using FT-IR, XPS, and XRD analyses to evaluate its additional properties. Notably, the optimal mass ratio of N-CNF to DAC@Ag1 was found to be 5:5, resulting in a substantial enhancement in mechanical properties, with a 139.8% increase in tensile elongation and a 33.1% increase in strength, reaching 10% and 125.24 MPa, respectively, compared to DAC@Ag1 alone. Furthermore, the inhibition zones against Escherichia coli and Staphylococcus aureus were significantly expanded to 7.9 mm and 15.9 mm, respectively, surpassing those of DAC@Ag1 alone by 154.8% and 467.9%, indicating remarkable improvements in antimicrobial efficacy. Mechanism analysis highlighted synergistic effects from chemical covalent bonding and hydrogen bonding in the DAC@Ag1/N-CNF, enhancing the mechanical and antimicrobial properties significantly. The addition of N-CNF markedly augmented the properties of the composite film, thereby facilitating its broader application in the antimicrobial field.

A Review on Barrier Properties of Cellulose/Clay Nanocomposite Polymers for Packaging Applications

Packaging materials are used to protect consumer goods, such as food, drinks, cosmetics, healthcare items, and more, from harmful gases and physical and chemical damage during storage, distribution, and handling. Synthetic plastics are commonly used because they exhibit sufficient characteristics for packaging requirements, but their end lives result in environmental pollution, the depletion of landfill space, rising sea pollution, and more. These exist because of their poor biodegradability, limited recyclability, etc. There has been an increasing demand for replacing these polymers with bio-based biodegradable materials for a sustainable environment. Cellulosic nanomaterials have been proposed as a potential substitute in the preparation of packaging films. Nevertheless, their application is limited due to their poor properties, such as their barrier, thermal, and mechanical properties, to name a few. The barrier properties of materials play a pivotal role in extending and determining the shelf lives of packaged foods. Nanofillers have been used to enhance the barrier properties. This article reviews the literature on the barrier properties of cellulose/clay nanocomposite polymers. Cellulose extraction stages such as pretreatment, bleaching, and nanoparticle isolation are outlined, followed by cellulose modification methods. Finally, a brief discussion on nanofillers is provided, followed by an extensive literature review on the barrier properties of cellulose/clay nanocomposite polymers. Although similar reviews have been presented, the use of modification processes applied to cellulose, clay, and final nanocomposites to enhance the barrier properties has not been reviewed. Therefore, this article focuses on this scope.

Understanding Nanocellulose-Water Interactions: Turning a Detriment into an Asset

Modern technology has enabled the isolation of nanocellulose from plant-based fibers, and the current trend focuses on utilizing nanocellulose in a broad range of sustainable materials applications. Water is generally seen as a detrimental component when in contact with nanocellulose-based materials, just like it is harmful for traditional cellulosic materials such as paper or cardboard. However, water is an integral component in plants, and many applications of nanocellulose already accept the presence of water or make use of it. This review gives a comprehensive account of nanocellulose-water interactions and their repercussions in all key areas of contemporary research: fundamental physical chemistry, chemical modification of nanocellulose, materials applications, and analytical methods to map the water interactions and the effect of water on a nanocellulose matrix.

Recent advancements, trends, fundamental challenges and opportunities in spray deposited cellulose nanofibril films for packaging applications

Plastic packaging is causing a serious environmental concern owing to its difficulty in degrading and micro-particulates' emissions. Developing biodegradable films has gained research attention to overcome ecological and health issues associated with plastic based packaging. One alternative substitute for petroleum-based plastic is nanocellulose based films, having distinguishing characteristics such as biodegradability, renewability, and non-toxicity. Nanocellulose is classified into three major types, i.e., cellulose nanofibril, cellulose nanocrystals, and bacterial nanocellulose. However, the scope of this review is limited to cellulose nanofibril (CNF) because this is the only one of major types that could be turned into film at a competitive cost with petroleum derived polymers. This paper provides a concise insight on the current trends and production methods of CNF. Additionally, the methods for transforming CNF into films are also discussed in this review. However, the focus of this review is the CNF films produced via spray deposition, their properties and applications, and fundamental challenges associated with their commercialization. Spray deposition or spray coating is an ideal candidate as a large-scale production technique of CNF films due to its remarkable features such as rapidity, flexibility, and continuity. Spray deposited CNF films exhibit excellent mechanical properties and oxygen barrier performance, while, possessing limited moisture barrier performance. The possible pathways to improve the moisture barrier performance and optical properties of these films are also discussed in this review. The existing publications on spray deposited CNF films are also highlighted from the literature. Finally, the current status of industrial production of these films and opportunities for academics and industries are also presented, indicating that fibre production capacity needs to be enhanced.

Multilayers of Renewable Nanostructured Materials with High Oxygen and Water Vapor Barriers for Food Packaging

Natural biopolymers have become key players in the preparation of biodegradable food packaging. However, biopolymers are typically highly hydrophilic, which imposes limitations in terms of barrier properties that are associated with water interactions. Here, we enhance the barrier properties of biobased packaging using multilayer designs, in which each layer displays a complementary barrier function. Oxygen, water vapor, and UV barriers were achieved using a stepwise assembly of cellulose nanofibers, biobased wax, and lignin particles supported by chitin nanofibers. We first engineered several designs containing CNFs and carnauba wax. Among them, we obtained low water vapor permeabilities in an assembly containing three layers, i.e., CNF/wax/CNF, in which wax was present as a continuous layer. We then incorporated a layer of lignin nanoparticles nucleated on chitin nanofibrils (LPChNF) to introduce a complete barrier against UV light, while maintaining film translucency. Our multilayer design which comprised CNF/wax/LPChNF enabled high oxygen (OTR of 3 ± 1 cm³/m²·day) and water vapor (WVTR of 6 ± 1 g/m²·day) barriers at 50% relative humidity. It was also effective against oil penetration. Oxygen permeability was controlled by the presence of tight networks of cellulose and chitin nanofibers, while water vapor diffusion through the assembly was regulated by the continuous wax layer. Lastly, we showcased our fully renewable packaging material for preservation of the texture of a commercial cracker (dry food). Our material showed functionality similar to that of the original packaging, which was composed of synthetic polymers.

Preparation and benchmarking of novel cellulose nanopaper

Synthetic polymers and plastics which are currently used as barrier materials in packaging applications are neither renewable nor biodegradable. Nanopaper, which is obtained by breaking down cellulose fibers into nanoscale particles, have unique properties with the potential to replace synthetic packaging materials, but requires very high energy to mechanically process the fibers into nanopaper. This research investigates whether refining alone can be used to produce nanopaper with sufficient quality for packaging applications. Nanopaper was produced from Bleached Eucalyptus Kraft (BEK) refined with a PFI mill and from Northern Bleached Softwood Kraft (NBSK) refined in a pilot disc refiner. Both trials found a plateau for oxygen permeability and water vapour permeability that was reached after 1800 kWh/t and 12,000 kWh/t for refining in the pilot disc refiner and PFI mill, respectively. Refining beyond these optima produced either little or no reduction in permeability, while increasing the drainage time to form a sheet. However, elastic modulus, strain at break and sheet light transmittance did continue to increase. The plateau oxygen permeability of ~ 1.24 (cc µm)/(m² day kPa) is 1-3 orders of magnitude lower than the oxygen permeability for PET and LDPE, respectively, while the plateau water vapour permeability ~ 3 × 10^-11 g/m.s. Pa was 1-2 orders of magnitude higher than for PET and LDPE. The improved strength and barrier properties of nanopaper achieved at lab and pilot scale mechanical refining process promises a sustainable alternative to conventional packaging.

SUPPLEMENTARY INFORMATION

The online version contains supplementary material available at 10.1007/s10570-022-04563-0.

Nanocelluloses as skin biocompatible materials for skincare, cosmetics, and healthcare: Formulations, regulations, and emerging applications

Nowadays, skin biocompatible products are fast-growing markets for nanocelluloses with increasing number of patents published in last decade. This review highlights recent developments, market trends, safety assessments, and regulations for different nanocellulose types (i.e. nanoparticles, nanocrystals, nanofibers, nanoyarns, bacterial nanocellulose) used in skincare, cosmetics, and healthcare. The specific properties of nanocelluloses for skincare include high viscosity and shear thinning properties, surface functionality, dispersion stability, water-holding capacity, purity, and biocompatibility. Depending on their morphology (e.g. size, aspect ratio, geometry, porosity), nanocelluloses can be used as formulation modifiers, moisturizers, nanofillers, additives, membranes, and films. Nanocellulose composite particles were recently developed as carriers for bioactive compounds or UV-blockers and platforms for wound healing and skin sensors. As toxicological assessment depends on morphologies and intrinsic properties, stringent regulation is needed from the testing of efficient nanocellulose dosages. The challenges and perspectives for an industrial breakthrough are related to optimization of production and processing conditions.

Advanced nanocellulose-based gas barrier materials: Present status and prospects

Nanocellulose based gas barrier materials have become an increasingly important subject, since it is a widespread environmentally friendly natural polymer. Previous studies have shown that super-high gas barrier can be achieved with pure and hierarchical nanocellulose films fabricated through simple suspension or layer-by-layer technique either by itself or incorporating with other polymers or nanoparticles. Improved gas barrier properties were observed for nanocellulose-reinforced composites, where nanocellulose partially impermeable nanoparticles decreased gas permeability effectively. However, for nanocellulose-based materials, the higher gas barrier performance is jeopardized by water absorption and shape deformation under high humidity conditions which is a challenge for maintaining properties in material applications. Thus, numerous investigations have been done to solve the problem of water absorption in nanocellulose-based materials. In this literature review, gas barrier properties of pure, layer-by-layer and composite nanocellulose films are investigated. The possible theoretical gas barrier mechanisms are described, and the prospects for nanocellulose-based materials are discussed.

Influence of Lactic Acid Surface Modification of Cellulose Nanofibrils on the Properties of Cellulose Nanofibril Films and Cellulose Nanofibril-Poly(lactic acid) Composites

In this study, cellulose nanofibrils (CNFs) were modified by catalyzed lactic acid esterification in an aqueous medium with SnCl2 as a catalyst. Films were made from unmodified and lactic acid-modified CNF without a polymer matrix to evaluate the effectiveness of the modification. Ungrafted and lactic acid-grafted CNF was also compounded with poly(lactic acid) (PLA) to produce composites. Mechanical, water absorption, and barrier properties were evaluated for ungrafted CNF, lactic acid-grafted CNF films, and PLA/CNF composites to ascertain the effect of lactic acid modification on the properties of the films and nanocomposites. FTIR spectra of the modified CNF revealed the presence of carbonyl peaks at 1720 cm-1, suggesting that the esterification reaction was successful. Modification of CNF with LA improved the tensile modulus of the produced films but the tensile strength and elongation decreased. Additionally, films made from modified CNF had lower water absorption, as well as water vapor and oxygen permeability, relative to their counterparts with unmodified CNFs. The mechanical properties of PLA/CNF composites made from lactic acid-grafted CNFs did not significantly change with respect to the ungrafted CNF. However, the addition of lactic acid-grafted CNF to PLA improved the water vapor permeability relative to composites containing ungrafted CNF. Therefore, the esterification of CNFs in an aqueous medium may provide an environmentally benign way of modifying the surface chemistry of CNFs to improve the barrier properties of CNF films and PLA/CNF composites.

Overview of Nanocellulose in Food Packaging

BACKGROUND

The rising concern with environmental preservation has led to increasing interest in biodegradable polymer composites from renewable sources, such as cellulose and its derivatives. The use of nanocellulose is an innovative food packaging trend.

DISCUSSION

This paper presents an overview and discusses the state of the art of different nanocellulose materials used in food and food packaging, and identifies important patents related to them. It is important to consider that before marketing, new products must be proven safe for consumers and the environment.

CONCLUSION

Several packaging materials using nanocellulose have been developed and shown to be promising for use as active and intelligent materials for food packaging. Other nanocellulose products are under investigation for packaging and may enter the market in the near future. Many countries have been adjusting their regulatory frameworks to deal with nanotechnologies, including nanocellulose packaging.

Nanocellulose in food packaging: A review

The research in eco-friendly and sustainable materials for packaging applications with enhanced barrier, thermo-mechanical, rheological and anti-bacterial properties has accelerated in the last decade. Last decade has witnessed immense interest in employing nanocellulose (NC) as a sustainable and biodegradable alternative to the current synthetic packaging barrier films. This review article gathers the research information on NC as a choice for food packaging material. It reviews on the employment of NC and its various forms including its chemico-physical treatments into bio/polymers and its impact on the performance of nanocomposites for food packaging application. The review reveals the fact that the research trends towards NC based materials are quite promising for Active Packaging (AP) applications, including the Controlled Release Packaging (CRP) and Responsive Packaging (RP). Finally, it summarizes with the challenges of sustainable packaging, gray areas that need an improvement/focus in order to commercially exploit this wonderful material for packaging application.

Multifunctionalized Cellulose Nanofiber for Water-Repellent and Wash-Sustainable Coatings on Fabrics

A new synthetic route was developed to modify cellulose nanofiber for water-repellent coatings with great sustainability after multiple washing cycles. Multiple functional groups were grafted on 2,2,6,6-tetramethylpiperidine 1-oxyl radical (TEMPO)-oxidized cellulose nanofibers (TOCN) to achieve superhydrophobic performance and strong adhesion on cotton cloth. First, hexadecylamine (HDA) was used to modify TOCN surface into hydrophobic derivatives via amidation. The amidation-modified TOCN (AMT) were then grafted with a polyisocyanate cross-linking agent (PCA). The final multimodified TOCN (MMT) had hydrophobic alkyls and isocyanate groups on the surface. These surface functional groups were confirmed by Fourier transform infrared spectroscopy (FTIR) and X-ray photoelectron spectroscopy (XPS). After spraying the MMT suspension on cotton fabrics, the isocyanate groups would react with hydroxyl groups on cotton fibers, leading to a uniform conformal layer of MMT on fabric surfaces. The MMT coating showed great water repellence and washing sustainability. A large contact angle of 150° and a small sliding angle of ∼10° were observed. The superhydrophobic performance retained even after 10 laundry washing cycles. Several examples were also demonstrated to show the capability and the possibility of applying this coating material for water-repellent applications.

Industrial Application of Nanocelluloses in Papermaking: A Review of Challenges, Technical Solutions, and Market Perspectives

Nanocelluloses (NC) increase mechanical and barrier paper properties allowing the use of paper in applications actually covered by other materials. Despite the exponential increase of information, NC have not been fully implemented in papermaking yet, due to the challenges of using NC. This paper provides a review of the main new findings and emerging possibilities in this field by focusing mainly on: (i) Decoupling the effects of NC on wet-end and paper properties by using synergies with retention aids, chemical modification, or filler preflocculation; (ii) challenges and solutions related to the incorporation of NC in the pulp suspension and its effects on barrier properties; and (iii) characterization needs of NC at an industrial scale. The paper also includes the market perspectives. It is concluded that to solve these challenges specific solutions are required for each paper product and process, being the wet-end optimization the key to decouple NC effects on drainage and paper properties. Furthermore, the effect of NC on recyclability must also be taken into account to reach a compromise solution. This review helps readers find upscale options for using NC in papermaking and identify further research needs within this field.

Organic-Inorganic Hybrid Planarization and Water Vapor Barrier Coatings on Cellulose Nanofibrils Substrates

Cellulose nanofibrils (CNF) can be produced in the form of thin, transparent and flexible films. However, the permeability of such materials to oxygen and water vapor is very sensitive to moisture, which limits their potential for a variety of packaging and encapsulation applications. Diffusion barrier coatings were thus developed to reduce the access of water molecules to enzymatically pre-treated and carboxymethylated CNF substrates. The coatings were based on UV curable organic-inorganic hybrids with epoxy, tetraethylorthosilicate (TEOS) and 3-glycidoxypropyltrimethylenesilane (GPTS) precursors and additional vapor formed SiN_x layers. A total of 14 monolayer and multilayer coatings with various thickness and hybrid composition were produced and analyzed. The water vapor transmission rate (WVTR) of the bilayer epoxy/CNF film was two times lower compared to that of uncoated CNF film. This was partly due to the water vapor permeability of the epoxy, a factor of two times lower than CNF. The epoxy coating improved the transparency of CNF, however it did not properly wet to the CNF surfaces and the interfacial adhesion was low. In contrast hybrid epoxy-silica coatings led to high adhesion levels owing to the formation of covalent interactions through condensation reactions with the OH-terminated CNF surface. The barrier and optical performance of hybrid coated CNF substrates was similar to that of CNF coated with pure epoxy. In addition, the hybrid coatings provided an excellent planarization effect, with roughness close to 1 nm, one to two orders of magnitude lower than that of the CNF substrates. The WVTR and oxygen transmission rate values of the hybrid coated CNF laminates were in the range 5–10 g/m²/day (at 38°C and 50% RH) and 3–6 cm³/m²/day/bar (at 23°C and 70% RH), respectively, which matches food and pharmaceutical packaging requirements. The permeability to water vapor of the hybrid coatings was moreover found to decrease with increasing the TEOS/GPTS ratio up to 30 wt% and then increase at higher ratio, and to be much lower for thinner coatings due to further UV-induced silanol condensation and faster evaporation of byproducts. The addition of a single 150 nm thick SiN_x layer on the hybrid coated CNF improved its water vapor barrier performance by more than 680 times, with WVTR below the 0.02 g/m²/day detection limit.

2,3-Dialdehyde nanofibrillated cellulose as a potential material for the treatment of MRSA infection

Nanocellulose materials have undergone rapid development in recent years as promising biomedical materials due to their excellent physical and biological properties, in particular their biocompatibility, biodegradability, and low cytotoxicity.

High performance green barriers based on nanocellulose

With the increasing environmental concerns such as sustainability and end-of-life disposal challenges, materials derived from renewable resources such as nanocellulose have been strongly advocated as potential replacements for packaging materials. Nanocellulose can be extracted from various plant resources through mechanical and chemical ways. Nanocellulose with its nanoscale dimensions, high crystalline nature, and the ability to form hydrogen bonds resulting in strong network makes it very hard for the molecules to pass through, suggesting excellent barrier properties associated with films made from these material. This review paper aim to summarize the recent developments in various barrier films based on nanocellulose with special focus on oxygen and water vapor barrier properties.