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.

Renewable and Functional Latexes Synthesized by Polymerization-Induced Self-Assembly for UV-Curable Films

After the development of polymer coatings and films based on renewable resources, there remains a challenge of combining the advantages of water-borne acrylic latexes with the excellent physical properties of cross-linked solvent-borne coatings. After polymerization, the renewable 4-oxocyclopentenyl acrylate (4CPA) is capable of undergoing photocyclodimerization under UV light, yielding a cross-linked polyacrylate. In this work, we investigate the polymerization-induced self-assembly (PISA) of 4CPA with several renewable acrylic monomers in the presence of a macro-RAFT agent. The produced latexes have a small particle size, good colloidal stability, and are free of volatile organic compounds. After film formation and UV curing, flexible to rigid films can be obtained depending on the monomer composition and UV irradiation time. The cross-linked films show promise as oil and water barriers in paper coating applications. This work outlines the development and application of renewable and functional cross-linkable latexes synthesized by PISA.

Design and fabrication of superhydrophobic cellulose nanocrystal films by combination of self-assembly and organocatalysis

Cellulose nanocrystals, which have unique properties of high aspect ratio, high surface area, high mechanical strength, and a liquid crystalline nature, constitute a renewable nanomaterial with great potential for several uses (e.g., composites, films and barriers). However, their intrinsic hydrophilicity results in materials that are moisture sensitive and exhibit poor water stability. This limits their use and competitiveness as a sustainable alternative against fossil-based materials/plastics in packaging, food storage, construction and materials application, which cause contamination in our oceans and environment. To make cellulose nanocrystal films superhydrophobic, toxic chemicals such as fluorocarbons are typically attached to their surfaces. Hence, there is a pressing need for environmentally friendly alternatives for their modification and acquiring this important surface property. Herein, we describe the novel creation of superhydrophobic, fluorocarbon-free and transparent cellulose nanocrystal films with functional groups by a bioinspired combination of self-assembly and organocatalytic surface modification at the nanoscale using food approved organic acid catalysts. The resulting film-surface is superhydrophobic (water contact angle > 150°) and has self-cleaning properties (the lotus effect). In addition, the superhydrophobic cellulose nanocrystal films have excellent water stability and significantly decreased oxygen permeability at high relative humidity with oxygen transmission rates better than those of commonly used plastics.

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.

Mechanical properties of cellulose nanofibril papers and their bionanocomposites: A review

Cellulose nanofibril (CNF) paper has various applications due to its unique advantages. Herein, we present the intrinsic mechanical properties of CNF papers, along with the preparation and properties of nanoparticle-reinforced CNF composite papers. The literature on CNF papers reveals a strong correlation between the intrafibrillar network structure and the resulting mechanical properties. This correlation is found to hold for all primary factors affecting mechanical properties, indicating that the performance of CNF materials depends directly on and can be tailored by controlling the intrafibrillar network of the system. The parameters that influence the mechanical properties of CNF papers were critically reviewed. Moreover, the effect on the mechanical properties by adding nanofillers to CNF papers to produce multifunctional composite products was discussed. We concluded this article with future perspectives and possible developments in CNFs and their bionanocomposite papers.

Deconstruction and Reassembly of Renewable Polymers and Biocolloids into Next Generation Structured Materials

This review considers the most recent developments in supramolecular and supraparticle structures obtained from natural, renewable biopolymers as well as their disassembly and reassembly into engineered materials. We introduce the main interactions that control bottom-up synthesis and top-down design at different length scales, highlighting the promise of natural biopolymers and associated building blocks. The latter have become main actors in the recent surge of the scientific and patent literature related to the subject. Such developments make prominent use of multicomponent and hierarchical polymeric assemblies and structures that contain polysaccharides (cellulose, chitin, and others), polyphenols (lignins, tannins), and proteins (soy, whey, silk, and other proteins). We offer a comprehensive discussion about the interactions that exist in their native architectures (including multicomponent and composite forms), the chemical modification of polysaccharides and their deconstruction into high axial aspect nanofibers and nanorods. We reflect on the availability and suitability of the latter types of building blocks to enable superstructures and colloidal associations. As far as processing, we describe the most relevant transitions, from the solution to the gel state and the routes that can be used to arrive to consolidated materials with prescribed properties. We highlight the implementation of supramolecular and superstructures in different technological fields that exploit the synergies exhibited by renewable polymers and biocolloids integrated in structured materials.

Engineering cellulose nanopaper with water resistant, antibacterial, and improved barrier properties by impregnation of chitosan and the followed halogenation

This work demonstrated a facile and sustainable approach to functionalize cellulose nanopaper (CNP) by impregnation of chitosan (CS) and the followed halogenation. It was found that the tensile strength of the functionalized CNP (CNP/CS-Cl) was enhanced by 38.3% and 512.6% at dry and wet conditions, respectively. Meanwhile, the total transmittance (at 550 nm) of CNP/CS-Cl was increased from 75% of pure CNP to 85%, with 35% decrease in optical haze. Moreover, the CNP/CS-Cl exhibited significant enhancement in barrier properties. Importantly, part of the amino groups on CS were transformed into N-halamines during the halogenation process, which endowed the CNP/CS-Cl with excellent antibacterial performance against both S. aureus and E. coli with 100% bacterial reduction after 10 min of contact. Thus, this work provides a simple and efficient approach to functionalize CNP with water resistance, high transparency, excellent antibacterial and barrier properties, which will expand the potential applications of CNP.

High-Oxygen-Barrier Multilayer Films Based on Polyhydroxyalkanoates and Cellulose Nanocrystals

This study reports on the development and characterization of organic recyclable high-oxygen-barrier multilayer films based on different commercial polyhydroxyalkanoate (PHA) materials, including a blend with commercial poly(butylene adipate-co-terephthalate) (PBAT), which contained an inner layer of cellulose nanocrystals (CNCs) and an electrospun hot-tack adhesive layer of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) derived from cheese whey (CW). As a result, the full multilayer structures were made from bio-based and/or compostable materials. A characterization of the produced films was carried out in terms of morphological, optical, mechanical, and barrier properties with respect to water vapor, limonene, and oxygen. Results indicate that the multilayer films exhibited a good interlayer adhesion and contact transparency. The stiffness of the multilayers was generally improved upon incorporation of the CNC interlayer, whereas the enhanced elasticity of the blend was reduced to some extent in the multilayer with CNCs, but this was still much higher than for the neat PHAs. In terms of barrier properties, it was found that 1 µm of the CNC interlayer was able to reduce the oxygen permeance between 71% and 86%, while retaining the moisture and aroma barrier of the control materials.

Aqueous Modification of Chitosan with Itaconic Acid to Produce Strong Oxygen Barrier Film

In this study, the chemical modification of chitosan using itaconic acid as a natural-based unsaturated dicarboxylic acid was investigated. In an aqueous environment, the amine group of chitosan reacts with itaconic acid to produce a chitosan derivative with pyrrolidone-4-carboxylic acid group. On the basis of the elemental analysis, 15% of the amine groups of chitosan reacted, thus creating modified chitosan with amine and carboxylic acid functionalities. Due to the presence of amine and carboxylic acid groups, the surface charge properties of the chitosan were notably altered after itaconic acid modification. In an aqueous solution, the modified chitosan exhibited zwitterionic properties, being cationic at low pH and turning anionic when the pH was increased over 6.5, whereas the original chitosan remained cationic until pH 9. Furthermore, it was demostrated that the modified chitosan was suitable for the preparation of a self-standing film with similarly high transparency but notably higher mechanical strength and oxygen barrier properties compared to a film made from the original chitosan. In addition, the thermal stability of the modified chitosan film was higher than that of the original chitosan film, and the modified chitosan exhibited flame-retardant properties.

Nanocellulose Bio-Based Composites for Food Packaging

The food industry is increasingly demanding advanced and eco-friendly sustainable packaging materials with improved physical, mechanical and barrier properties. The currently used materials are synthetic and non-degradable, therefore raising environmental concerns. Consequently, research efforts have been made in recent years towards the development of bio-based sustainable packaging materials. In this review, the potential of nanocelluloses as nanofillers or as coatings for the development of bio-based nanocomposites is discussed, namely: (i) the physico-chemical interaction of nanocellulose with the adjacent polymeric phase, (ii) the effect of nanocellulose modification/functionalization on the final properties of the composites, (iii) the production methods for such composites, and (iv) the effect of nanocellulose on the overall migration, toxicity, and the potential risk to human health. Lastly, the technology readiness level of nanocellulose and nanocellulose based composites for the market of food packaging is discussed.

Transparent, Flexible, and Strong 2,3-Dialdehyde Cellulose Films with High Oxygen Barrier Properties

2,3-Dialdehyde cellulose (DAC) of a high degree of oxidation (92% relative to AGU units) prepared by oxidation of microcrystalline cellulose with sodium periodate (48 °C, 19 h) is soluble in hot water. Solution casting, slow air drying, hot pressing, and reinforcement by cellulose nanocrystals afforded films (∼100 μm thickness) that feature intriguing properties: they have very smooth surfaces (SEM), are highly flexible, and have good light transmittance for both the visible and near-infrared range (89–91%), high tensile strength (81–122 MPa), and modulus of elasticity (3.4–4.0 GPa) depending on hydration state and respective water content. The extraordinarily low oxygen permeation of <0.005 cm³ μm m^–2 day^–1 kPa^–1 (50% RH) and <0.03 cm³ μm m^–2 day^–1 kPa^–1 (80% RH) can be regarded as a particularly interesting feature of DAC films. The unusually high initial contact angle of about 67° revealed a rather low hydrophilicity compared to other oxidatively modified or unmodified cellulosic materials which is most likely the result of inter- and intramolecular hemiacetal and hemialdal formation during drying and pressing.

Sustainable Boron Nitride Nanosheet-Reinforced Cellulose Nanofiber Composite Film with Oxygen Barrier without the Cost of Color and Cytotoxicity

This paper introduces a boron nitride nanosheet (BNNS)-reinforced cellulose nanofiber (CNF) film as a sustainable oxygen barrier film that can potentially be applied in food packaging. Most commodity plastics are oxygen-permeable. CNF exhibits an ideal oxygen transmission rate (OTR) of <1 cc/m²/day in highly controlled conditions. A CNF film typically fabricated by the air drying of a CNF aqueous solution reveals an OTR of 19.08 cc/m²/day. The addition of 0⁻5 wt % BNNS to the CNF dispersion before drying results in a composite film with highly improved OTR of 4.7 cc/m²/day, which is sufficient for meat and cheese packaging. BNNS as a 2D nanomaterial increases the pathway of oxygen gas and reduces the chances of pinhole formation during film fabrication involving water drying. In addition, BNNS improves the mechanical properties of the CNF films (Young's modulus and tensile strength) without significant elongation reductions, probably due to the good miscibility of CNF and BNNS in the aqueous solution. Addition of BNNS also produces negligible color change, which is important for film aesthetics. An in vitro cell experiment was performed to reveal the low cytotoxicity of the CNF/BNNS composite. This composite film has great potential as a sustainable high-performance food-packaging material.

Nanocellulose in green food packaging

The development of packaging materials with new functionalities and lower environmental impact is now an urgent need of our society. On one hand, the shelf-life extension of packaged products can be an answer to the exponential increase of worldwide demand for food. On the other hand, uncertainty of crude oil prices and reserves has imposed the necessity to find raw materials to replace oil-derived polymers. Additionally, consumers' awareness toward environmental issues increasingly pushes industries to look with renewed interest to "green" solutions. In response to these issues, numerous polymers have been exploited to develop biodegradable food packaging materials. Although the use of biopolymers has been limited due to their poor mechanical and barrier properties, these can be enhanced by adding reinforcing nanosized components to form nanocomposites. Cellulose is probably the most used and well-known renewable and sustainable raw material. The mechanical properties, reinforcing capabilities, abundance, low density, and biodegradability of nanosized cellulose make it an ideal candidate for polymer nanocomposites processing. Here we review the potential applications of cellulose based nanocomposites in food packaging materials, highlighting the several types of biopolymers with nanocellulose fillers that have been used to form bio-nanocomposite materials. The trends in nanocellulose packaging applications are also addressed.

Characterization of Pores in Dense Nanopapers and Nanofibrillated Cellulose Membranes: A Critical Assessment of Established Methods

Nanofibrillated cellulose (NFC) is a natural fibrous material that can be readily processed into membranes. NFC membranes for fluid separation work in aqueous medium, thus in their swollen state. The present study is devoted to a critical investigation of porosity, pore volume, specific surface area, and pore size distribution of dry and wet NFC nanopapers, also known as membranes, with various established techniques, such as electron microscopy, helium pycnometry, mercury intrusion, gas adsorption (N2 and Kr), and thermoporometry. Although these techniques can be successfully applied to inorganic materials (e.g., mesoporous silica), it is necessary to appraise them for organic and hydrophilic products such as NFC membranes. This is due to different phenomena occurring at the materials interfaces with the probing fluids. Mercury intrusion and gas adsorption are often used for the characterization of porosity-related properties; nevertheless, both techniques characterize materials in the dry state. In parallel, thermoporometry was employed to monitor the structure changes upon swelling, and a water permeance test was run to show the accessibility of the membranes to fluids. For the first time, the methods were systematically screened, and we highlighted the need of uniform sample treatments prior to the measurements (i.e., sample cutting and outgassing protocols) in order to harmonize results from the literature. The need for revising the applicability range of mercury intrusion and the inappropriateness of nitrogen adsorption were pointed out. We finally present a table for selecting the most appropriate method to determine a desired property and propose guidelines for results interpretation from which future users could profit.

Composite Films of Poly(vinyl alcohol) and Bifunctional Cross-linking Cellulose Nanocrystals

Long and flexible cellulose nanofibrils or stiff and short cellulose nanocrystals (CNCs) are both promising lightweight materials with high strength and the potential to serve as reinforcing agents in many polymeric materials. In this study, bifunctional reactive cellulose nanocrystals (RCNCs) with carboxyl and aldehyde functionalities were used as reinforcements to prepare acetal-bonding cross-linked poly(vinyl alcohol) (PVA) films. Two RCNCs were obtained through the mechanical homogenization of partially carboxylated dialdehyde cellulose (DAC) with a residual aldehyde content of 0.55 and 1.93 mmol/g and a carboxyl content of 1.65 and 1.93 mmol/g, respectively. The mechanical, thermal, and barrier properties of PVA-RCNC films with a variable mass ratio of RCNCs (0.5-10%) were determined. Reference CNCs without reactive aldehydes were obtained through the reduction of aldehyde functionalities to primary hydroxide groups, and their reinforcing effect was compared to RCNCs. With the addition of 10% acetal-bonding RCNCs with respect to PVA weight, the tensile strength and Young's modulus were up to 2-fold greater than those of pure PVA film. An addition of only 0.5% RCNCs improved the tensile strength of the PVA film by 66% and the modulus by 61%. In comparison, a significantly lower reinforcing effect (19% with CNC loading of 0.5%) was found using reference CNCs. PVA's effective oxygen barrier and thermal properties were preserved when RCNCs were introduced into the films.