Ductility and Toughness Improvement of Injection-Molded Compostable Pieces of Polylactide by Melt Blending with Poly(ε-caprolactone) and Thermoplastic Starch

Phase morphology, rheological behavior and mechanical properties of supertough biobased poly(lactic acid) reactive ternary blends

Poly(lactic acid) (PLA) is one of the most promising bio-based polyester with great potential to replace for the petroleum-based polymers, which can significantly reduce greenhouse gas emissions. However, the inherent brittleness of PLA seriously restricts its broad applications. Herein, PLA/poly(ε-caprolactone) (PCL)/ethylene methyl acrylate-glycidyl methacrylate (EMA-GMA) ternary blends with different phase structures were prepared through reactive blending. The reactions between the epoxy groups of EMA-GMA and the carboxyl and hydroxyl end groups of PLA and PCL and were evidenced from the Fourier transform infrared spectroscopy, dynamic mechanical analysis and rheological results. The atomic force microscopy (AFM) images clearly revealed the formation of stack structure of the PCL and EMA-GMA minor phases in PLA/PCL/EMA-GMA (80/15/5) blend, and core-shell particle structures in PLA/PCL/EMA-GMA (80/10/10) and (80/5/15) blends. In terms of elongation at break and impact toughness, PLA/PCL/EMA-GMA (80/5/15) blend presents the best properties among all the compositions. Moreover, it also behaved excellent stiffness-toughness balance. The toughening mechanism can be ascribed to the formation of core-shell structure and the existence of interfacial adhesion in the ternary blends. This work can provide guide for the preparation and design of PLA-based partially renewable supertough materials that can compete with conventional petro-derived plastics.

Effect of Almond Skin Waste and Glycidyl Methacrylate on Mechanical and Color Properties of Poly(ε-caprolactone)/Poly(lactic acid) Blends

Blending Poly(lactic acid) (PLA) and Poly(ε-caprolactone) (PCL) is a promising strategy to enhance the properties of biodegradable materials. However, these compounds are thermodynamically immiscible and, consequently, compatibilization is required during polymer blending. Reinforced biocomposites can be obtained by adding agricultural wastes generated by industries which are forced to consider waste treatment methods to prevent environmental concerns. Novel PCL/PLA blends were proposed based on the addition of 10 wt.% almond shell (AS) waste combined with 3 wt.% glycidyl methacrylate (GMA) as a compatibilizer. Different PCL-, PLA-, and PCL/PLA-based blends at different percentages (75:25, 50:50, 25:75, 15:85) added with GMA and AS were obtained. The color results highlighted the lower transparency and brownish tone of the studied formulations after the addition of AS. The addition of PCL provided a positive effect on PLA's ductility due to its intrinsically higher flexibility. The combination of GMA and AS improved the mechanical properties of PCL, PLA, and 50:50 controls by reducing yield strength, yield strength at break, and elongation at break values. The 75:25_GMA_AS formulation showed a homogeneous visual appearance, low transparency, and desirable mechanical properties for rigid food packaging applications, reducing the final material cost through the revalorization of AS.

Polycaprolactone with Glass Beads for 3D Printing Filaments

At present, 3D printing is experiencing a great boom. The demand for new materials for 3D printing is also related to its expansion. This paper deals with manufacturing innovative polymer composite filaments suitable for the Fused Filament Fabrication method in 3D printing. As a filler, common and uncostly glass beads were used and mixed with biocompatible and biodegradable poly (ε-caprolactone), as a polymer matrix. This material was characterized via several physical-chemical methods. The Youngs modulus was increasing by about 30% with 20% loading of glass beads, and simultaneously, brittleness and elongations were decreased. The glass beads do not affect the shore hardness of filaments. The rheological measurement confirmed the material stability in a range of temperatures 75–120 °C. The presented work aimed to prepare lightweight biocompatible, cheap material with appropriate mechanical properties, lower printing temperature, and good printing processing. We can assess that the goal was fully met, and these filaments could be used for a wide range of applications.

Valorization of Liquor Waste Derived Spent Coffee Grains for the Development of Injection-Molded Polylactide Pieces of Interest as Disposable Food Packaging and Serving Materials

The present work puts the Circular Bioeconomy's concept into action, originally valorizing residues of spent coffee grains from the beverage liquor coffee industry to develop green composite pieces of polylactide (PLA). The as-received spent coffee grains were first milled to obtain the so-called spent coffee grounds (SCGs) that were, thereafter, incorporated at 20 wt.% into PLA by extrusion. Finally, the resultant green composite pellets were shaped into pieces by injection molding. Moreover, two oligomers of lactic acid (OLAs), namely OLA2 and OLA2_mal, the latter being functionalized with maleic anhydride (MAH), were added with SCGs during the extrusion process at 10 wt.%. The results show that, opposite to most claims published in the literature of green composites of PLA, the incorporation of the liquor waste derived SCGs increased the ductility of the pieces by approximately 280% mainly due to their high lipid content. Moreover, the simultaneous addition of OLA2 and OLA2_mal further contributed to improve the tensile strength of the green composite pieces by nearly 36% and 60%, respectively. The higher performance of OLA2_mal was ascribed to the chemical interaction achieved between the biopolyester and the lignocellulosic fillers by the MAH groups. The resultant green composite pieces are very promising as disposable food-serving utensils and tableware.

In Situ Chemical Modification of Thermoplastic Starch with Poly(L-lactide) and Poly(butylene succinate) for an Effectively Miscible Ternary Blend

Thermoplastic starch (TPS) is in situ ring-opening polymerized with L-lactide (L-LA) and directly condensed with a poly(butylene succinate) (PBS) prepolymer in an extruder using two different production pathways to demonstrate the concept “like dissolves like” in a miscible poly(lactide)/TPS/PBS (PLA/TPS/PBS) ternary blend. The TPS crystalline pattern changes from a V_H-type to an E_H-type after TPS modification with a hydrophobic-PLLA segment. Heteronuclear multiple-bond correlation confirmed the successful formation of PLLA-TPS-PBS copolymers via two different in situ chemical modification pathways (i.e., (I) step-by-step modification and (II) one-pot reaction). All obtained PLLA-TPS-PBS copolymers functioned as the miscible phase, enhancing PLA/PLLA-TPS-PBS/PBS ternary blend miscibility, especially the random structural PLLA-TPS-PBS-II copolymers created in an in situ one-pot reaction. However, the PLLA-TPS-PBS-I copolymers can enhance PBS crystallization only. While the random PLLA-TPS-PBS-II copolymers exhibit a homogeneous multi-phase dispersion and crystallization acceleration in both the PLA and PBS chains. Moreover, the storage modulus level of the PLA/PLLA-TPS-PBS-II/PBS ternary blend remains high with a downward temperature shift in the glass transition region, indicating a stronger and more flexible system. The practical achievement of in situ modified TPS and, consequently, a miscible PLA/PLLA-TPS-PBS/PBS ternary blend with favorable physical properties, reveal its potential application in both compostable and food contact packaging.

Quality and Shelf-Life Stability of Pork Meat Fillets Packaged in Multilayer Polylactide Films

In the present study, the effectiveness of a multilayer film of polylactide (PLA), fully bio-based and compostable, was ascertained to develop a novel sustainable packaging solution for the preservation of fresh pork meat. To this end, the multilayer PLA films were first characterized in terms of their thermal characteristics, structure, mechanical performance, permeance to water and aroma vapors and oxygen, and optical properties and, for the first time, compared with two commercial high-barrier multilayer packaging films. Thereafter, the multilayers were thermosealed to package fillets of fresh pork meat and the physicochemical changes, lipid oxidation levels, and microbiological counts were monitored in the food samples during storage under refrigeration conditions. Results showed that the meat fillets packaged in PLA developed a redder color and showed certain indications of dehydration and oxidation, being more noticeably after 11 days of storage, due to the higher water vapor and oxygen permeance values of the biopolymer multilayer. However, the pH changes and bacterial growth in the cold-stored fresh pork meat samples were minimal and very similar in the three tested multilayer films, successfully accomplishing the requirements of the food quality and safety standards at the end of storage.

Biodegradable Thermoplastic Starch/Polycaprolactone Blends with Co-Continuous Morphology Suitable for Local Release of Antibiotics

We report a reproducible preparation and characterization of highly homogeneous thermoplastic starch/pol(ε‑caprolactone) blends (TPS/PCL) with a minimal thermomechanical degradation and co-continuous morphology. These materials would be suitable for biomedical applications, specifically for the local release of antibiotics (ATB) from the TPS phase. The TPS/PCL blends were prepared in the whole concentration range. In agreement with theoretical predictions based on component viscosities, the co-continuous morphology was found for TPS/PCL blends with a composition of 70/30 wt.%. The minimal thermomechanical degradation of the blends was achieved by an optimization of the processing conditions and by keeping processing temperatures as low as possible, because higher temperatures might damage ATB in the final application. The blends’ homogeneity was verified by scanning electron microscopy. The co-continuous morphology was confirmed by submicron-computed tomography. The mechanical performance of the blends was characterized in both microscale (by an instrumented microindentation hardness testing; MHI) and macroscale (by dynamic thermomechanical analysis; DMTA). The elastic moduli of TPS increased ca four times in the TPS/PCL (70/30) blend. The correlations between elastic moduli measured by MHI and DMTA were very strong, which implied that, in the future studies, it would be possible to use just micromechanical testing that does not require large specimens.

On the Use of Paper Sludge as Filler in Biocomposites for Injection Moulding

The potential use of paper sludge (PS) as filler in the production of bio-composites based on poly lactic acid (PLA) and polybutylene adipate terephthalate (PBAT) was investigated. PS/PLA/PBAT composites, with addition of acetyl tributyl citrate (ATBC) as biobased plasticizer, were produced with PS loadings up to 30 wt.% by twin-screw extrusion followed by injection moulding. The composites were characterized by rheological measurements, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC) and mechanical tests (tensile and impact resistance) to study the effect of PS on the processability, thermal stability, crystallinity and mechanical performance of polymeric matrix. The optimized composites at higher PS content were successfully processed to produce pots for horticulture and, in view of this application, preliminary phytotoxicity tests were conducted using the germination test on Lepidium sativum L. seeds. Results revealed that developed composites up to 30 wt.% PS had good processability by extrusion and injection moulding showing that PS is a potential substitute of calcium carbonate as filler in the production of bio-composites, and the absence of phytotoxic effects showed the possibility of their use in the production of pots/items for applications in floriculture and/or horticulture.

Structure and properties of in situ reactive blend of polylactide and thermoplastic starch

In this study, in situ reactive extrusion of polylactide and thermoplastic starch modified with chloropropyl trimethoxysilane coupling agent (PLA/mTPS) is proposed. The success of covalent bond formation between PLA matrix and mTPS phase is clarified by two-dimensional nuclear magnetic resonance (2D-NMR) spectroscopy with ¹H¹H TOCSY mode. This chemically bound PLA with starch gives the remarkable compatibility in the PLA/mTPS film, with not only a decreased glass transition temperature (47 °C) but also an increased crystallinity of PLA (Χ_c of 50%). It consequently increases oxygen barrier significantly and also enhances the film flexibility as observed from the drastic increase of elongation at break (from 3% to 50%). Moreover, the PLA/mTPS 60/40 (w/w) film exhibits the accelerated degradation as compared with pure PLA film.

Preparation and Characterization of Nonwoven Fibrous Biocomposites for Footwear Components

Chromium-tanned leathers used in the manufacture of footwear and leather goods pose an environmental problem because they contain harmful chemicals and are very difficult to recycle. A solution to this problem can be composite materials from tree leaves, fruit residues and other fibrous agricultural products, which can replace chromium-tanned leather. The present study describes the preparation of biocomposite leather-like materials from microbial cellulose and maple leave fibers as bio-fillers. The formulation was optimized by design of experiment and the prepared biocomposites characterized by tensile test, FTIR, DMA, SEM, adhesion test, volume porosity, water absorptivity, surface wettability and shape stability. From the viewpoint of future use in the footwear industry, results obtained showed that the optimized material was considerably flexible with tensile strength of 2.13 ± 0.29 MPa, elastic modulus of 76.93 ± 1.63 MPa and porosity of 1570 ± 146 mL/min. In addition, the material depicted good shape stability and surface adhesive properties. The results indicate that a suitable treatment of biomass offers a way to prepare exploitable nonwoven fibrous composites for the footwear industry without further burdening the environment.

Reducing cytotoxicity of poly (lactic acid)-based/zinc oxide nanocomposites while boosting their antibacterial activities by thymol for biomedical applications

In the present study, ternary blends based on poly (lactic acid)/poly (ε-caprolactone)/thermoplastic starch were prepared at different concentrations of synthesized zinc oxide nanoparticles (ZnO-NPs) and thymol. The sizes of ZnO-NPs with an average diameter of about 30-50 nm were detected by FE-SEM analysis. Moreover, the effect of ZnO-NPs and thymol on morphological, FT-IR spectrum, UV absorption, thermal stability, cytotoxicity, and antibacterial properties of neat blend was investigated. TGA analysis showed that the addition of ZnO-NPs and/or thymol diminished thermal stability of the system. Incorporating ZnO-NPs improved antibacterial activities of the neat blend, but MTT-assay and AO fluorescent staining test results depicted a decrease in cell viability to less than 20% by the addition of 5 wt% ZnO-NPs. In such a condition, the addition of thymol to the nanocomposites exhibited a dose-dependent increase in cell survival mostly due to thymol antioxidant properties. Interestingly, the antibacterial performance of compounds was also improved by the presence of thymol. Therefore, the obtained nanocomposites have potential to extend applications of innovative biomedical devices for future research in which both high cell viability and superior antibacterial properties are needed such as an antibacterial wound healing film.

Environmentally Friendly Polymers and Polymer Composites

In the last decade, continuous research advances have been observed in the field of environmentally friendly polymers and polymer composites due to the dependence of polymers on fossil fuels and the sustainability issues related to plastic wastes. This research activity has become much more intense in the food packaging industry due to the high volume of waste it generates. Biopolymers are nowadays considered as among the most promising materials to solve these environmental problems. However, they still show inferior performance regarding both processability and end-use application. Blending currently represents a very cost-effective strategy to increase the ductility and impact resistance of biopolymers. Furthermore, different lignocellulosic materials are being explored to be used as reinforcing fillers in polymer matrices for improving the overall properties, lower the environmental impact, and also reduce cost. Moreover, the use of vegetable oils, waste derived liquids, and essential oils opens up novel opportunities as natural plasticizers, reactive compatibilizers or even active additives for the development of new polymer formulations with enhanced performance and improved sustainability profile.

Torrefaction of Coffee Husk Flour for the Development of Injection-Molded Green Composite Pieces of Polylactide with High Sustainability

Coffee husk, a major lignocellulosic waste derived from the coffee industry, was first ground into flour of fine particles of approximately 90 µm and then torrefied at 250 °C to make it more thermally stable and compatible with biopolymers. The resultant torrefied coffee husk flour (TCHF) was thereafter melt-compounded with polylactide (PLA) in contents from 20 to 50 wt% and the extruded green composite pellets were shaped by injection molding into pieces and characterized. Although the incorporation of TCHF reduced the ductility and toughness of PLA, filler contents of 20 wt% successfully yielded pieces with balanced mechanical properties in both tensile and flexural conditions and improved hardness. Contents of up to 30 wt% of TCHF also induced a nucleating effect that favored the formation of crystals of PLA, whereas the thermal degradation of the biopolyester was delayed by more than 7 °C. Furthermore, the PLA/TCHF pieces showed higher thermomechanical resistance and their softening point increased up to nearly 60 °C. Therefore, highly sustainable pieces were developed through the valorization of large amounts of coffee waste subjected to torrefaction. In the Circular Bioeconomy framework, these novel green composites can be used in the design of compostable rigid packaging and food contact disposables.

Covas J. Assessment of the Mechanical and Thermal Properties of Injection-Molded Poly(3-hydroxybutyrate-co-3-hydroxyhexanoate)/Hydroxyapatite Nanoparticles Parts for Use in Bone Tissue Engineering

In the present study, poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) [P(3HB-co-3HHx)] was reinforced with hydroxyapatite nanoparticles (nHA) to produce novel nanocomposites for potential uses in bone reconstruction. Contents of nHA in the 2.5-20 wt % range were incorporated into P(3HB-co-3HHx) by melt compounding and the resulting pellets were shaped into parts by injection molding. The addition of nHA improved the mechanical strength and the thermomechanical resistance of the microbial copolyester parts. In particular, the addition of 20 wt % of nHA increased the tensile (Et) and flexural (Ef) moduli by approximately 64% and 61%, respectively. At the highest contents, however, the nanoparticles tended to agglomerate, and the ductility, toughness, and thermal stability of the parts also declined. The P(3HB-co-3HHx) parts filled with nHA contents of up to 10 wt % matched more closely the mechanical properties of the native bone in terms of strength and ductility when compared with metal alloys and other biopolymers used in bone tissue engineering. This fact, in combination with their biocompatibility, enables the development of nanocomposite parts to be applied as low-stress implantable devices that can promote bone reconstruction and be reabsorbed into the human body.

Development of Injection-Molded Polylactide Pieces with High Toughness by the Addition of Lactic Acid Oligomer and Characterization of Their Shape Memory Behavior

This work reports the effect of the addition of an oligomer of lactic acid (OLA), in the 5-20 wt% range, on the processing and properties of polylactide (PLA) pieces prepared by injection molding. The obtained results suggested that the here-tested OLA mainly performs as an impact modifier for PLA, showing a percentage increase in the impact strength of approximately 171% for the injection-molded pieces containing 15 wt% OLA. A slight plasticization was observed by the decrease of the glass transition temperature (Tg) of PLA of up to 12.5 °C. The OLA addition also promoted a reduction of the cold crystallization temperature (Tcc) of more than 10 °C due to an increased motion of the biopolymer chains and the potential nucleating effect of the short oligomer chains. Moreover, the shape memory behavior of the PLA samples was characterized by flexural tests with different deformation angles, that is, 15°, 30°, 60°, and 90°. The obtained results confirmed the extraordinary effect of OLA on the shape memory recovery (Rr) of PLA, which increased linearly as the OLA loading increased. In particular, the OLA-containing PLA samples were able to successfully recover over 95% of their original shape for low deformation angles, while they still reached nearly 70% of recovery for the highest angles. Therefore, the present OLA can be successfully used as a novel additive to improve the toughness and shape memory behavior of compostable packaging articles based on PLA in the new frame of the Circular Economy.

Biopolymers as bone substitutes: a review

Human bones have unique structures and characteristics, and replacing a natural bone in the case of bone fracture or bone diseases is a very complicated problem. The main goal of this paper was to summarize the recent research on polymer materials as bone substitutes and for bone repair. Bone treatment methods, bone substitute materials as well as their advantages and drawbacks, and manufacturing methods were reviewed. Biopolymers are the most promising materials in the field of artificial bones and using biopolymers with the shape memory effect can improve the integration of an artificial bone into the human body by better mimicking the structure and properties of natural bones, decreasing the invasiveness of surgical procedures by producing deployable implants. It has been shown that the application of the rapid prototyping technology for artificial bones allows the customization of bone substitutes for a patient and the creation of artificial bones with a complex structure.

Enhanced Interfacial Adhesion of Polylactide/Poly(ε-caprolactone)/Walnut Shell Flour Composites by Reactive Extrusion with Maleinized Linseed Oil

Novel green composites were prepared by melt compounding a binary blend of polylactide (PLA) and poly(ε-caprolactone) (PCL) at 4/1 (wt/wt) with particles of walnut shell flour (WSF) in the 10–40 wt % range, which were obtained as a waste from the agro-food industry. Maleinized linseed oil (MLO) was added at 5 parts per hundred resin (phr) of composite to counteract the intrinsically low compatibility between the biopolymer blend matrix and the lignocellulosic fillers. Although the incorporation of WSF tended to reduce the mechanical strength and thermal stability of PLA/PCL, the MLO-containing composites filled with up to 20 wt % WSF showed superior ductility and a more balanced thermomechanical response. The morphological analysis revealed that the performance improvement attained was related to a plasticization phenomenon of the biopolymer blend and, more interestingly, to an enhancement of the interfacial adhesion of the green composites achieved by extrusion with the multi-functionalized vegetable oil.