Development and Characterization of Fully Renewable and Biodegradable Polyhydroxyalkanoate Blends with Improved Thermoformability

Biodegradation behavior of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) containing phenolic compounds in seawater in laboratory testing conditions

Biodegradation in marine medium of PHBV films with or without 5 % wt. of phenolic compounds (catechin, ferulic acid, and vanillin) was assessed at laboratory scale. Respirometric analyses and film disintegration kinetics were used to monitor the process over a period of 162 days. Structural changes in the films were analyzed throughout the exposure period using FESEM, DSC, Thermogravimetric analyses, XRD, and FTIR spectra. Respirometric tests showed complete biodegradation of all materials during the exposure period (the biodegradation half-time ranged between 63 and 79 days) but at different rates, depending on the phenolic compound incorporated. Ferulic acid and vanillin accelerate the PHBV biodegradation, whereas catechin delayed the process. Disintegration kinetics confirmed these results and showed that degradation occurred from the surface to the interior of the films. This was controlled by the degradation rate of the polymer amorphous phase and the formation of a biomass coating on the film surface. This is the result of the compounds generated by polymer degradation in combination with excretions from microorganisms. This coating has the potential to affect the enzyme diffusion to the polymer substrate. Moreover, the cohesion forces of the amorphous phase (reflected in its glass transition temperature) affected its degradation rate, while the slower degrading crystalline fragments were released, thus contributing to the disintegration process on the film's surface. Ferulic acid, with its hydrolytic effect, enhanced degradation, as did vanillin for its plasticizing and weakening effect in the amorphous phase of polymer matrix. In contrast, catechin with cross-linking effect hindered the progress of the material degradation, considerably slowing down the process rate.

Production and functionalization strategies for superior polyhydroxybutyrate blend performance

This study investigates the effects of blending poly(3-hydroxybutyrate) (PHB) with microcrystalline cellulose (MCC), polylactic acid (PLA), lignin, and polyethylene glycol (PEG) on the properties of the resulting composite materials. Using a melt blending method, the composites were characterized by scanning electron microscopy (SEM), nuclear magnetic resonance (NMR), and thermogravimetric analysis (TGA). The results reveal that blending PHB with MCC, PLA, lignin, and PEG significantly enhances the thermal stability, mechanical strength, and biodegradability of the composites compared to pure PHB. Specifically, the tensile strength of PHB-PLA blends increased by up to 47.77 MPa, compared to 27.16 MPa for pure PHB. The blend with 50 % cellulose content showed the highest tensile strength of 54.91 MPa. TGA results show that the PHB-MCC and PHB-lignin blends exhibit improved thermal stability, with onset degradation temperatures rising to 294.8 °C, compared to 275 °C for pure PHB. Moreover, the PHB-lignin blend demonstrated a gradual weight loss starting at 200 °C and continuing until about 350 °C. SEM images of the blends indicate a uniform microstructure, contributing to the improved mechanical properties. The PHB-PEG blend demonstrated an elongation at break of 4.34 %, significantly higher than the 2.15 % for pure PHB, highlighting its suitability for applications requiring pliable materials. The biodegradability tests showed that PHB-PLA blends maintained consistent degradation rates, making them advantageous for applications needing controlled biodegradability. These findings suggest that blending PHB with MCC, PLA, lignin, and PEG can produce materials with enhanced properties suitable for applications in packaging, biomedical devices, and other areas where both performance and sustainability are essential.

Influence of the 3-Hydroxyvalerate Content on the Processability, Nucleating and Blending Ability of Poly(3-Hydroxybutyrate-co-3-hydroxyvalerate)-Based Materials

Poly(3-hydroxybutyrate-co-3-hydroxyvalerate (P(3HB-co-3HV) copolymers are an attractive class of biopolymers whose properties can be tailored by changing the 3-hydroxyvalerate monomer (3HV) concentration, offering the possibility of counteracting problems related to high crystallinity, brittleness, and processability. However, there are few studies about the effects of 3HV content on the processability of copolymers. The present study aims to provide new insights into the effect of 3HV content on the processing step including common practices like compounding, addition of nucleation agents and/or amorphous polymers as plasticizers. P(3HB-co-3HV)-based films containing 3, 18, and 28 mol % 3HV were processed into films by extrusion and subsequent molding. The characterization results confirmed that increasing the 3HV content from 3 to 28 mol % resulted in a decrease in the melting point (from 175 to 100 °C) and an improvement in mechanical properties (i.e., elongation at break from 7 ± 1% to 120 ± 3%). The behavior of P(3HB-co-3HV) in the presence of additives was also investigated. It was shown that an increase in the 3HV content leads to better miscibility with amorphous polymers.

Production and Characterization of Melt-Spun Poly(3-hydroxybutyrate)/Poly(3-hydroxybutyrate-co-4-hydroxybutyrate) Blend Monofilaments

We investigated the melt-spinning potential of a poly(3-hydroxybutyrate)/poly(3-hydroxybutyrate-co-4-hydroxybutyrate) blend using a piston spinning machine with two different spinneret diameters (0.2 and 0.5 mm). Results from the differential scanning calorimetry, dynamic mechanical thermal analysis, and tensile testing showed distinct filament properties depending on the monofilaments' cross-sectional area. Finer filaments possessed different melting behaviors compared to the coarser filaments and the neat polymer, indicating the formation of a different type of polymer crystal. Additionally, the mechanical properties of the finer filament (tensile strength: 21.5 MPa and elongation at break: 341%) differed markedly from the coarser filament (tensile strength: 11.7 MPa, elongation at break: 12.3%). The hydrolytic stability of the filaments was evaluated for 7 weeks in a phosphate-buffered saline solution and showed a considerably reduced elongation at break of the thinner filaments. Overall, the results indicate considerable potential for further filament improvements to facilitate textile processing.

Active Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) Films Containing Phenolic Compounds with Different Molecular Structures

To obtain more sustainable and active food packaging materials, PHBV films containing 5% wt. of phenolic compounds with different molecular structures (ferulic acid, vanillin, and catechin) and proved antioxidant and antimicrobial properties were obtained by melt blending and compression molding. These were characterized by their structural, mechanical, barrier, and optical properties, as well as the polymer crystallization, thermal stability, and component migration in different food simulants. Phenolic compounds were homogenously integrated within the polymer matrix, affecting the film properties differently. Ferulic acid, and mainly catechin, had an anti-plasticizing effect (increasing the polymer glass transition temperature), decreasing the film extensibility and the resistance to breaking, with slight changes in the elastic modulus. In contrast, vanillin provoked a plasticizing effect, decreasing the elastic modulus without notable changes in the film extensibility while increasing the water vapor permeability. All phenolic compounds, mainly catechin, improved the oxygen barrier capacity of PHBV films and interfered with the polymer crystallization, reducing the melting point and crystallinity degree. The thermal stability of the material was little affected by the incorporation of phenols. The migration of passive components of the different PHBV films was lower than the overall migration limit in every simulant. Phenolic compounds were released to a different extent depending on their thermo-sensitivity, which affected their final content in the film, their bonding forces in the polymer matrix, and the simulant polarity. Their effective release in real foods will determine their active action for food preservation. Catechin was the best preserved, while ferulic acid was the most released.

Polyhydroxybutyrate-co-hydroxyvalerate (PHBV) with Phenolic Acids for Active Food Packaging

PHBV films incorporating 3, 6 and 9% ferulic acid (FA) or p-coumaric acid (PCA) were obtained by melt blending and compression moulding. The films' microstructures and thermal behaviours were analysed as well as their mechanical, optical and barrier properties. The overall and specific migration of the materials in different food simulants was also characterised. FA was homogeneously mixed with the polymer, whereas PCA was mainly dispersed as fine particles in the PHBV matrices due to its higher melting point. These structural features promoted differences in the physical properties of the films depending on the compound concentration. As the concentration of both compounds rose, the barrier capacity of the films to oxygen, and to a lesser extent water vapour, was enhanced. While FA promoted the extensibility of the films, 9% PCA enhanced their brittleness. Both compounds affected the crystallisation pattern of the polymer, promoting smaller crystalline formations and a slight decrease in crystallinity. Although the overall migration of every film formulation was lower than the overall migration limit (OML), the release of active compounds was dependent on the food simulant; almost total release was noted in ethanol containing simulants but was more limited in aqueous systems. Therefore, these films could be used as food contact materials, contributing to extending the food's shelf life.

Poly(3-hydroxybutyrate) nanocomposites modified with even and odd chain length polyhydroxyalkanoates

Poly(3-hydroxybutyrate) (PHB) was blended with medium-chain-length PHAs (mcl-PHAs) for improving its flexibility while nanocellulose (NC) was added as a reinforcing agent. Even and odd-chain-length PHAs, having as main component poly(3-hydroxyoctanoate) (PHO) or poly(3-hydroxynonanoate) (PHN) were synthesized and served as PHB modifiers. The effects of PHO and PHN on the morphology, thermal, mechanical and biodegradation behaviors of PHB were different, especially in the presence of NC. The addition of mcl-PHAs decreased the storage modulus (E') of PHB blends by about 40 %. The further addition of NC mitigated this decrease bringing the E' of PHB/PHO/NC close to that of PHB and having a minor effect on the E' of PHB/PHN/NC. The biodegradability of PHB/PHN/NC was higher than that of PHB/PHO/NC, the latter's being close to that of neat PHB after soil burial for four months. The results showed a complex effect of NC, which enhanced the interaction between PHB and mcl-PHAs and decreased the size of PHO/PHN inclusions (1.9 ± 0.8/2.6 ± 0.9 μm) while increasing the accessibility of water and microorganisms during soil burial. The blown film extrusion test showed the ability of mcl-PHA and NC modified PHB to stretch forming uniform tube and supports the application of these biomaterials in the packaging sector.

Development and Characterization of Thermoformed Bilayer Trays of Paper and Renewable Succinic Acid Derived Biopolyester Blends and Their Application to Preserve Fresh Pasta

The present study reports on the development by thermoforming of highly sustainable trays based on a bilayer structure composed of paper substrate and a film made of a blend of partially bio-based poly(butylene succinate) (PBS) and poly(butylene succinate-co-adipate) (PBSA). The incorporation of the renewable succinic acid derived biopolyester blend film slightly improved the thermal resistance and tensile strength of paper, whereas its flexural ductility and puncture resistance were notably enhanced. Furthermore, in terms of barrier properties, the incorporation of this biopolymer blend film reduced the water and aroma vapor permeances of paper by two orders of magnitude, while it endowed the paper structure with intermediate oxygen barrier properties. The resultant thermoformed bilayer trays were, thereafter, originally applied to preserve non-thermally treated Italian artisanal fresh pasta, "fusilli calabresi" type, which was stored under refrigeration conditions for 3 weeks. Shelf-life evaluation showed that the application of the PBS-PBSA film on the paper substrate delayed color changes and mold growth for 1 week, as well as reduced drying of fresh pasta, resulting in acceptable physicochemical quality parameters within 9 days of storage. Lastly, overall migration studies performed with two food simulants demonstrated that the newly developed paper/PBS-PBSA trays are safe since these successfully comply with current legislation on plastic materials and articles intended to come into contact with food.

Electrospun Multilayered Films Based on Poly(3-hydroxybutyrate-co-3-hydroxyvalerate), Copolyamide 1010/1014, and Electrosprayed Nanostructured Silica

In this research, bio-based electrospun multilayered films for food packaging applications with good barrier properties and close to superhydrophobic behavior were developed. For this purpose, two different biopolymers, a low-melting point and fully bio-based synthetic aliphatic copolyamide 1010/1014 (PA1010/1014) and the microbially synthesized poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) and food-contact-complying organomodified silica (SiO₂) nanostructured microparticles, were processed by electrospinning. The production of the multilayer structure was finally obtained by means of a thermal post-treatment, with the aim to laminate all of the components by virtue of the so-called interfiber coalescence process. The so developed fully electrospun films were characterized according to their morphology, their permeance to water vapor and oxygen, the mechanical properties, and their water contact angle properties. Interestingly, the annealed electrospun copolyamide did not show the expected improved barrier behavior as a monolayer. However, when it was built into a multilayer form, the whole assembly exhibited a good barrier, an improved mechanical performance compared to pure PHBV, an apparent water contact angle of ca. 146°, and a sliding angle of 8°. Consequently, these new biopolymer-based multilayer films could be a bio-based alternative to be potentially considered in more environmentally friendly food packaging strategies.

Green and Sustainable Hot Melt Adhesive (HMA) Based on Polyhydroxyalkanoate (PHA) and Silanized Cellulose Nanofibers (SCNFs)

Polyhydroxyalkanoate (PHA), with a long chain length and high poly(4-hydroxybutyric acid) (P4HB) ratio, can be used as a base polymer for eco-friendly and biodegradable adhesives owing to its high elasticity, elongation at break, flexibility, and processability; however, its molecular structures must be adjusted for adhesive applications. In this study, surface-modified cellulose nanofibers (CNFs) were used as a hydrophobic additive for the PHA-based adhesive. For the surface modification of CNFs, double silanization using tetraethyl orthosilicate (TEOS) and methyltrimethoxysilane (MTMS) was performed, and the thermal and structural properties were evaluated. The hydrophobicity of the TEOS- and MTMS-treated CNFs (TMCNFs) was confirmed by FT-IR and water contact angle analysis, with hydrophobic CNFs well dispersed in the PHA. The PHA-CNFs composite was prepared with TMCNFs, and its morphological analysis verified the good dispersion of TMCNFs in the PHA. The tensile strength of the composite was enhanced when 10% TMCNFs were added; however, the viscosity decreased as the TMCNFs acted as a thixotropic agent. Adding TMCNFs to PHA enhanced the flowability and infiltration ability of the PHA-TMCNFs-based adhesive, and an increase in the loss tangent (Tan δ) and adjustment of viscosity without reducing the adhesive strength was also observed. These changes in properties can improve the flowability and dispersibility of the PHA-TMCNFs adhesive on a rough adhesive surface at low stress. Thus, it is expected that double-silanized CNFs effectively improve their interfacial adhesion in PHA and the adhesive properties of the PHA-CNFs composites, which can be utilized for more suitable adhesive applications.

Upgrading cardoon biomass into Polyhydroxybutyrate based blends: A holistic approach for the synthesis of biopolymers and additives

Cardoon, Cynara cardunculus L. represents a biorefinery crop with a great potential in the bioplastic field. This work investigates the valorization of different cardoon components into high added value products, finally recombined into novel upgraded bioplastics. Bioprocesses for Polyhydroxybutyrate (PHB) and medium-chain-length Polyhydroxyalkanoates (mcl-PHA) production were set up starting from root inulin and seed oil respectively, highlighting the effect of process conditions on polymer properties. The ternary blend, in which the PHB polymer matrix was added with mcl-PHA and epoxidized cardoon oil, evidenced a synergic effect of both additives in modulating PHB structural and thermal properties, promoted by the physical interaction occurring among the components. This proof-of concept frames the paper in the holistic approach of circular economy applied to bioplastic production.

Influence of Ulluco Starch Modified by Annealing on the Physicochemical Properties of Biodegradable Films

This work aimed to evaluate the use of annealing (ANN) ulluco starch in the preparation of biodegradable films and its impact on the physicochemical properties of the materials. Three film samples (FS1, FS2, and FS3) were prepared at a fixed starch concentration (2.6% w/v) using glycerol as a plasticizer and then compared to a control sample (FSC) prepared with native ulluco starch. The physical, mechanical, and thermal properties of the films were evaluated. The use of ANN starch decreased the solubility (from 21.8% to 19.5%) and the swelling power (from 299% to 153%) of the film samples. In addition, an increase in opacity and relative crystallinity (from 7.54% to 10.5%) were observed. Regarding the thermal properties, all the samples presented high stability to degradation, with degradation temperatures above 200 °C. However, the samples showed deficiencies in their morphology, which affected the barrier properties. The use of ANN starch has some advantages over native starch in preparing films. However, more analysis is needed to improve the barrier properties of the materials. This work reveals the potential of the ANN ulluco starch for biodegradable film preparation. In addition, the use of modified ulluco starch is an alternative to add value to the crop, as well as to replace non-biodegradable materials used in the preparation of packaging.