Processing and Properties of Polyhydroxyalkanoate/ZnO Nanocomposites: A Review of Their Potential as Sustainable Packaging Materials

The escalating environmental concerns associated with conventional plastic packaging have accelerated the development of sustainable alternatives, making food packaging a focus area for innovation. Bioplastics, particularly polyhydroxyalkanoates (PHAs), have emerged as potential candidates due to their biobased origin, biodegradability, and biocompatibility. PHAs stand out for their good mechanical and medium gas permeability properties, making them promising materials for food packaging applications. In parallel, zinc oxide (ZnO) nanoparticles (NPs) have gained attention for their antimicrobial properties and ability to enhance the mechanical and barrier properties of (bio)polymers. This review aims to provide a comprehensive introduction to the research on PHA/ZnO nanocomposites. It starts with the importance and current challenges of food packaging, followed by a discussion on the opportunities of bioplastics and PHAs. Next, the synthesis, properties, and application areas of ZnO NPs are discussed to introduce their potential use in (bio)plastic food packaging. Early research on PHA/ZnO nanocomposites has focused on solvent-assisted production methods, whereas novel technologies can offer additional possibilities with regard to industrial upscaling, safer or cheaper processing, or more specific incorporation of ZnO NPs in the matrix or on the surface of PHA films or fibers. Here, the use of solvent casting, melt processing, electrospinning, centrifugal fiber spinning, miniemulsion encapsulation, and ultrasonic spray coating to produce PHA/ZnO nanocomposites is explained. Finally, an overview is given of the reported effects of ZnO NP incorporation on thermal, mechanical, gas barrier, UV barrier, and antimicrobial properties in ZnO nanocomposites based on poly(3-hydroxybutyrate), poly(3-hydroxybutyrate-co-3-hydroxyvalerate), and poly(3-hydroxybutyrate-co-3-hydroxyhexanoate). We conclude that the functionality of PHA materials can be improved by optimizing the ZnO incorporation process and the complex interplay between intrinsic ZnO NP properties, dispersion quality, matrix-filler interactions, and crystallinity. Further research regarding the antimicrobial efficiency and potential migration of ZnO NPs in food (simulants) and the End-of-Life will determine the market potential of PHA/ZnO nanocomposites as active packaging material.

Microbial production of poly(3-hydroxybutyrate-co-3-hydroxyvalerate), from lab to the shelf: A review

Polyhydroxyalkanoates (PHAs) are natural biopolyesters produced by microorganisms that represent one of the most promising candidates for the replacement of conventional plastics due to their complete biodegradability and advantageous material properties which can be modulated by varying their monomer composition. Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) [P(3HB-co-3HV)] has received particular research attention because it can be synthesized based on the same microbial platform developed for poly(3-hydroxybutyrate) [P(3HB)] without much modification, with as high productivity as P(3HB). It also offers more useful mechanical and thermal properties than P(3HB), which broaden its application as a biocompatible and biodegradable polyester. However, a significant commercial disadvantage of P(3HB-co-3HV) is its rather high production cost, thus many studies have investigated the economical synthesis of P(3HB-co-3HV) from structurally related and unrelated carbon sources in both wild-type and recombinant microbial strains. A large number of metabolic engineering strategies have also been proposed to tune the monomer composition of P(3HB-co-3HV) and thus its material properties. In this review, recent metabolic engineering strategies designed for enhanced production of P(3HB-co-3HV) are discussed, along with their current status, limitations, and future perspectives.

Fabrication of Poly(3-hydroxybutyrate-co-3-hydroxyhexanoate)/ZnO Nanocomposite Films for Active Packaging Applications: Impact of ZnO Type on Structure-Property Dynamics

Bio-based and biodegradable polyhydroxyalkanoates (PHAs) have great potential as sustainable packaging materials. The incorporation of zinc oxide nanoparticles (ZnO NPs) could further improve their functional properties by providing enhanced barrier and antimicrobial properties, although current literature lacks details on how the characteristics of ZnO influence the structure-property relationships in PHA/ZnO nanocomposites. Therefore, commercial ZnO NPs with different morphologies (rod-like, spherical) and silane surface modification are incorporated into poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBHHx) via extrusion and compression molding. All ZnO NPs are homogeneously distributed in the PHBHHx matrix at 1, 3 and 5 wt.%, but finer dispersion is achieved with modified ZnO. No chemical interactions between ZnO and PHBHHx are observed due to a lack of hydroxyl groups on ZnO. The fabricated nanocomposite films retain the flexible properties of PHBHHx with minimal impact of ZnO NPs on crystallization kinetics and the degree of crystallinity (53 to 56%). The opacity gradually increases with ZnO loading, while remaining translucent up to 5 wt.% ZnO and providing an effective UV barrier. Improved oxygen barrier and antibacterial effects against S. aureus are dependent on the intrinsic characteristics of ZnO rather than its morphology. We conclude that PHBHHx retains its favorable processing properties while producing nanocomposite films that are suitable as flexible active packaging materials.

Recent Development of Polyhydroxyalkanoates (PHA)-Based Materials for Antibacterial Applications: A Review

The diseases caused by microorganisms are innumerable existing on this planet. Nevertheless, increasing antimicrobial resistance has become an urgent global challenge. Thus, in recent decades, bactericidal materials have been considered promising candidates to combat bacterial pathogens. Recently, polyhydroxyalkanoates (PHAs) have been used as green and biodegradable materials in various promising alternative applications, especially in healthcare for antiviral or antiviral purposes. However, it lacks a systematic review of the recent application of this emerging material for antibacterial applications. Therefore, the ultimate goal of this review is to provide a critical review of the state of the art recent development of PHA biopolymers in terms of cutting-edge production technologies as well as promising application fields. In addition, special attention was given to collecting scientific information on antibacterial agents that can potentially be incorporated into PHA materials for biological and durable antimicrobial protection. Furthermore, the current research gaps are declared, and future research perspectives are proposed to better understand the properties of these biopolymers as well as their possible applications.

Development and Characterization of Electrospun Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) Biopapers Containing Cerium Oxide Nanoparticles for Active Food Packaging Applications

Food quality is mainly affected by oxygen through oxidative reactions and the proliferation of microorganisms, generating changes in its taste, odor, and color. The work presented here describes the generation and further characterization of films with active oxygen scavenging properties made of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) loaded with cerium oxide nanoparticles (CeO₂NPs) obtained by electrospinning coupled to a subsequent annealing process, which could be used as coating or interlayer in a multilayer concept for food packaging applications. The aim of this work is to explore the capacities of these novel biopolymeric composites in terms of O₂ scavenging capacity, as well as antioxidant, antimicrobial, barrier, thermal, and mechanical properties. To obtain such biopapers, different ratios of CeO₂NPs were incorporated into a PHBV solution with hexadecyltrimethylammonium bromide (CTAB) as a surfactant. The produced films were analyzed in terms of antioxidant, thermal, antioxidant, antimicrobial, optical, morphological and barrier properties, and oxygen scavenging activity. According to the results, the nanofiller showed some reduction of the thermal stability of the biopolyester but exhibited antimicrobial and antioxidant properties. In terms of passive barrier properties, the CeO₂NPs decreased the permeability to water vapor but increased the limonene and oxygen permeability of the biopolymer matrix slightly. Nevertheless, the oxygen scavenging activity of the nanocomposites showed significant results and improved further by incorporating the surfactant CTAB. The PHBV nanocomposite biopapers developed in this study appear as very interesting constituents for the potential design of new active organic recyclable packaging materials.

Thermally Treated Berberine-Loaded SA/PVA/PEO Electrospun Microfiber Membranes for Antibacterial Wound Dressings

This study aimed to develop a safe and advanced antibacterial material of electrospun microfiber membranes (MFMs) for wound dressings. Combinations of several materials were investigated; thermal treatment and electrospinning techniques were used to form the best quality of MFMs to suit its end applications. By comparing the fiber morphology, diameter changes, and fracture strength, the suitable ratio of raw materials and thermal treatment were obtained before and after adding Trition X-100 as a surfactant for MFMs of sodium alginate/polyvinyl alcohol/polyethylene oxide (SA/PVA/PEO). The electrospinning solution was mixed with berberine as an antibacterial substance; meanwhile, calcium chloride (CaCl₂) was used as the crosslinking agent. The antibacterial properties, water dissolution resistance, water content, and fracture strength were thoroughly investigated. The results showed that the antibacterial rates of MFMs with different mass fractions of berberine (0, 3, and 5 wt.%) to Escherichia coli (E. coli) were 14.7, 92.9, and 97.2%, respectively. The moisture content and fracture strength of MFMs containing 5 wt.% berberine were 72.0% and 7.8 MPa, respectively. In addition, the produced MFMs embodied great water dissolution resistance. Berberine-loaded SA/PVA/PEO MFMs could potentially serve as an antibacterial wound dressing substrate with low cost and small side effects.

Advances in the Sensing and Treatment of Wound Biofilms

Wound biofilms represent a particularly challenging problem in modern medicine. They are increasingly antibiotic resistant and can prevent the healing of chronic wounds. However, current treatment and diagnostic options are hampered by the complexity of the biofilm environment. In this review, we present new chemical avenues in biofilm sensors and new materials to treat wound biofilms, offering promise for better detection, chemical specificity, and biocompatibility. We briefly discuss existing methods for biofilm detection and focus on novel, sensor-based approaches that show promise for early, accurate detection of biofilm formation on wound sites and that can be translated to point-of-care settings. We then discuss technologies inspired by new materials for efficient biofilm eradication. We focus on ultrasound-induced microbubbles and nanomaterials that can both penetrate the biofilm and simultaneously carry active antimicrobials and discuss the benefits of those approaches in comparison to conventional methods.

Advances in the Sensing and Treatment of Wound Biofilms

Wound biofilms represent a particularly challenging problem in modern medicine. They are increasingly antibiotic resistant and can prevent the healing of chronic wounds. However, current treatment and diagnostic options are hampered by the complexity of the biofilm environment. In this review, we present new chemical avenues in biofilm sensors and new materials to treat wound biofilms, offering promise for better detection, chemical specificity, and biocompatibility. We briefly discuss existing methods for biofilm detection and focus on novel, sensor-based approaches that show promise for early, accurate detection of biofilm formation on wound sites and that can be translated to point-of-care settings. We then discuss technologies inspired by new materials for efficient biofilm eradication. We focus on ultrasound-induced microbubbles and nanomaterials that can both penetrate the biofilm and simultaneously carry active antimicrobials and discuss the benefits of those approaches in comparison to conventional methods.

Transcrystalline growth of PLLA on carbon fiber grafted with nano-SiO2 towards boosting interfacial bonding in bone scaffold

BACKGROUND

The reinforcement effect of fiber-reinforced polymer composites is usually limited because of the poor interfacial interaction between fiber and polymer, though fiber reinforcement is regarded as an effective method to enhance the mechanical properties of polymer.

METHODS

In this study, nano-SiO2 particles grafted by 3-Glycidoxypropyltrimethoxysilane (KH560) were introduced onto the surface of 3-Aminopropyltriethoxysilane (KH550) modified carbon fiber (CF) by a self-assembly strategy to improve the interfacial bonding between CF and biopolymer poly (lactic acid) (PLLA).

RESULTS

The results indicated that PLLA chains preferred to anchor at the surface of nano-SiO2 particles and then formed high order crystalline structures. Subsequently, PLLA spherulites could epitaxially grow on the surface of functionalized CF, forming a transcrystalline structure at the CF/PLLA interface. Meanwhile, the nano-SiO2 particles were fixed in the transcrystalline structure, which induced a stronger mechanical locking effect between CF and PLLA matrix. The results of tensile experiments indicated that the PLLA/CF-SiO2 scaffold with a ratio of CF to SiO2 of 9:3 possessed the optimal strength and modulus of 10.11 MPa and 1.18 GPa, respectively. In addition, in vitro tests including cell adhesion and fluorescence indicated that the scaffold had no toxicity and could provide a suitable microenvironment for the growth and proliferation of cell.

CONCLUSION

In short, the PLLA/CF-SiO2 scaffold with good mechanical properties and cytocompatibility had great potential in the application of bone tissue engineering.

Living Lactobacillus-ZnO nanoparticles hybrids as antimicrobial and antibiofilm coatings for wound dressing application

Probiotic bacteria are able to produce antimicrobial substances as well as to synthesize green metal nanoparticles (NPs). New antimicrobial and antibiofilm coatings (LAB-ZnO NPs), composed of Lactobacillus strains and green ZnO NPs, were employed for the modification of gum Arabic-polyvinyl alcohol-polycaprolactone nanofibers matrix (GA-PVA-PCL) against Escherichia coli, Staphylococcus aureus, Pseudomonas aeruginosa and Candida albicans. The physicochemical properties of ZnO NPs biologically synthesized by L. plantarum and L. acidophilus, LAB-ZnO NPs hybrids and LAB-ZnO NPs@GA-PVA-PCL were studied using FE-SEM, EDX, EM, FTIR, XRD and ICP-OES. The morphology of LAB-ZnO NPs hybrids was spherical in range of 4.56-91.61 nm with an average diameter about 34 nm. The electrospun GA-PVA-PCL had regular, continuous and without beads morphology in the scale of nanometer and micrometer with an average diameter of 565 nm. Interestingly, the LAB not only acted as a biosynthesizer in the green synthesis of ZnO NPs but also synergistically enhanced the antimicrobial and antibiofilm efficacy of LAB-ZnO NPs@GA-PVA-PCL. Moreover, the low cytotoxicity of ZnO NPs and ZnO NPs@GA-PVA-PCL on the mouse embryonic fibroblasts cell line led to make them biocompatible. These results suggest that LAB-ZnO NPs@GA-PVA-PCL has potential as a safe promising antimicrobial and antibiofilm dressing in wound healing against pathogens.

Development and Advantages of Biodegradable PHA Polymers Based on Electrospun PHBV Fibers for Tissue Engineering and Other Biomedical Applications

Biodegradable polymeric biomaterials offer a significant advantage in disposable or fast-consuming products in medical applications. Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) is an example of a polyhydroxyalkanoate (PHA), i.e., one group of natural polyesters that are byproducts of reactions taking place in microorganisms in conditions with an excess carbon source. PHA polymers are a promising material for the production of everyday materials and biomedical applications. Due to the high number of monomers in the group, PHAs permit modifications enabling the production of copolymers of different compositions and with different proportions of individual monomers. In order to change and improve the properties of polymer fibers, PHAs are combined with either other natural and synthetic polymers or additives of inorganic phases. Importantly, electrospun PHBV fibers and mats showed an enormous potential in both the medical field (tissue engineering scaffolds, plasters, wound healing, drug delivery systems) and industrial applications (filter systems, food packaging). This Review summarizes the current state of the art in processing PHBV, especially by electrospinning, its degradation processes, and biocompatibility studies, starting from a general introduction to the PHA group of polymers.

Eugenol-acacia gum-based bifunctional nanofibers as a potent antifungal transdermal substitute

Aim: Fungal biofilms interfere with the wound healing processes. Henceforth, the study aims to fabricate a biomaterial-based nano-scaffold with the dual functionalities of wound healing and antibiofilm activity. Methods: Nanofibers comprising acacia gum, polyvinyl alcohol and inclusion complex of eugenol in β-cyclodextrin (EG-NF) were synthesized using electrospinning. Antibiofilm studies were performed on Candida species, and the wound-healing activity was evaluated through an in vivo excision wound rat model. Results: The EG-NF potentially eradicated the mature biofilm of Candida species and their clinical isolates. Further, EG-NF also enhanced the re-epithelization and speed of wound healing in in vivo rat experiments. Conclusion: The study established the bifunctional applications of eugenol nanofibers as a transdermal substitute with antifungal potency.

Preparation of Barbed ZnO Fibers and the Selective Adsorption Behavior for BSA

ZnO electrospun nanofibers can act as seed fibers to fabricate multidentate barbed fibers perpendicular to the growth of the fibers using the chemical bath deposition (CBD) method. Fibers with a multirod morphology have a porous grid structure. The sample is easy to recover, and the nonpolar surface in the sample is sufficiently exposed. In the research of barbed fiber fabrication and adsorption on bovine serum albumin (BSA), the effects of different chemical bath conditions on the growth of ZnO nanorods were discussed. Barbed fibers with large slenderness ratios were obtained at a water content of 60 mL at 75 °C. Each milligram of barbed fibers can quickly adsorb about 162 μg of protein within 30 min. The adsorption activity of BSA between polar and nonpolar ZnO surfaces was also studied. The selective adsorption behavior of BSA on the nonpolar surface was revealed.

Electrospinning nanofibrous graft preparation and wound healing studies using ZnO nanoparticles and glucosamine loaded with poly(methyl methacrylate)/polyethylene glycol

As wound dressing materials, electrospun nanofibrous scaffolds have a lot of promise. Electrospun nanofibrous scaffolds in combination with ZnO nanoparticles have antimicrobial and antioxidant properties, making electrospinning a successful technique for wound dressings.

Rapid eco-friendly synthesis, characterization, and cytotoxic study of trimetallic stable nanomedicine: A potential material for biomedical applications

In the current scenario of the fight against cancer Integration of potential elements seems to be the best alternative since it overcomes the weaknesses of individuals and the combination of elements makes them formidable in the fight against the cancer war. Inspired by this objective and trusting our knowledge of paddy straw grown oyster mushroom, Pleurotus florida (Pf) mediated synthesis; a first-of-kind approach has been developed for the rapid synthesis of Au-Pt-Ag trimetallic nanoparticles (TMNPs). The developed method was successful, which was confirmed by Ultraviolet-Visible, X-ray diffraction, Transmission Electron Microscopy, Energy Dispersive Spectroscopy. Specifically, prepared TMNPs have been studied for their stability and size as a primary prerequisite for nanomedicine. Finally, the stable nanomedicine developed has been assessed for its performance against the highly metastatic breast cancer cell line (mda-mb-231). The performance was assessed using MTT assay and morphological readings, which were integrated with the cell viability data. We also determined the IC50 value, which was far superior to individual components and motivated us to postulate the possible breast cancer cell killing mechanism of TMNPs. The present study unlocks the new paths for the mushroom-mediated environmentally friendly, economic synthesis of trimetallic nanoparticles, which can be effectively used in cancer nanomedicine.

Development of Active Barrier Multilayer Films Based on Electrospun Antimicrobial Hot-Tack Food Waste Derived Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) and Cellulose Nanocrystal Interlayers

Active multilayer films based on polyhydroxyalkanoates (PHAs) with and without high barrier coatings of cellulose nanocrystals (CNCs) were herein successfully developed. To this end, an electrospun antimicrobial hot-tack layer made of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) derived from cheese whey, a by-product from the dairy industry, was deposited on a previously manufactured blown film of commercial food contact PHA-based resin. A hybrid combination of oregano essential oil (OEO) and zinc oxide nanoparticles (ZnONPs) were incorporated during the electrospinning process into the PHBV nanofibers at 2.5 and 2.25 wt%, respectively, in order to provide antimicrobial properties. A barrier CNC coating was also applied by casting from an aqueous solution of nanocellulose at 2 wt% using a rod at 1m/min. The whole multilayer structure was thereafter assembled in a pilot roll-to-roll laminating system, where the blown PHA-based film was located as the outer layers while the electrospun antimicrobial hot-tack PHBV layer and the barrier CNC coating were placed as interlayers. The resultant multilayer films, having a final thickness in the 130-150 µm range, were characterized to ascertain their potential in biodegradable food packaging. The multilayers showed contact transparency, interlayer adhesion, improved barrier to water and limonene vapors, and intermediate mechanical performance. Moreover, the films presented high antimicrobial and antioxidant activities in both open and closed systems for up to 15 days. Finally, the food safety of the multilayers was assessed by migration and cytotoxicity tests, demonstrating that the films are safe to use in both alcoholic and acid food simulants and they are also not cytotoxic for Caco-2 cells.

A Review on Enhancing the Antibacterial Activity of ZnO: Mechanisms and Microscopic Investigation

Metal oxide nanomaterials are one of the preferences as antibacterial active materials. Due to its distinctive electronic configuration and suitable properties, ZnO is one of the novel antibacterial active materials. Nowadays, researchers are making a serious effort to improve the antibacterial activities of ZnO by forming a composite with the same/different bandgap semiconductor materials and doping of ions. Applying capping agents such as polymers and plant extract that control the morphology and size of the nanomaterials and optimizing different conditions also enhance the antibacterial activity. Forming a nanocomposite and doping reduces the electron/hole recombination, increases the surface area to volume ratio, and also improves the stability towards dissolution and corrosion. The release of antimicrobial ions, electrostatic interaction, reactive oxygen species (ROS) generations are the crucial antibacterial activity mechanism. This review also presents a detailed discussion of the antibacterial activity improvement of ZnO by forming a composite, doping, and optimizing different conditions. The morphological analysis using scanning electron microscopy, field emission-scanning electron microscopy, field-emission transmission electron microscopy, fluorescence microscopy, and confocal microscopy can confirm the antibacterial activity and also supports for developing a satisfactory mechanism. Graphical abstract showing the metal oxides antibacterial mechanism and the fluorescence and scanning electron microscopic images.