Enhancement of paperboard performance as packaging material by layering with plasticized polyhydroxybutyrate/nanocellulose coatings

Innovative biomaterials for food packaging: Unlocking the potential of polyhydroxyalkanoate (PHA) biopolymers

Polyhydroxyalkanoate (PHA) biopolyesters show a good balance between sustainability and performance, making them a competitive alternative to conventional plastics for ecofriendly food packaging. With an emphasis on developments over the last decade (2014-2024), this review examines the revolutionary potential of PHAs as a sustainable food packaging material option. It also delves into the current state of commercial development, competitiveness, and the carbon footprint associated with PHA-based products. First, a critical examination of the challenges experienced by PHAs in terms of food packaging requirements is undertaken, followed by an assessment of contemporary strategies addressing permeability, mechanical properties, and processing considerations. The various PHA packaging end-of-life options, including a comprehensive overview of the environmental impact and potential solutions will also be discussed. Finally, conclusions and future perspectives are elucidated with a view of prospecting PHAs as future green materials, with a blend of performance and sustainability of food packaging solutions.

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.

Approaches in Sustainable, Biobased Multilayer Packaging Solutions

The depletion of fossil resources and the growing demand for plastic waste reduction has put industries and academic researchers under pressure to develop increasingly sustainable packaging solutions that are both functional and circularly designed. In this review, we provide an overview of the fundamentals and recent advances in biobased packaging materials, including new materials and techniques for their modification as well as their end-of-life scenarios. We also discuss the composition and modification of biobased films and multilayer structures, with particular attention to readily available drop-in solutions, as well as coating techniques. Moreover, we discuss end-of-life factors, including sorting systems, detection methods, composting options, and recycling and upcycling possibilities. Finally, regulatory aspects are pointed out for each application scenario and end-of-life option. Moreover, we discuss the human factor in terms of consumer perception and acceptance of upcycling.

Poly(3-hydroxybutyrate) Nanocomposites with Cellulose Nanocrystals

Poly(3-hydroxybutyrate) (PHB) is one of the most promising substitutes for the petroleum-based polymers used in the packaging and biomedical fields due to its biodegradability, biocompatibility, good stiffness, and strength, along with its good gas-barrier properties. One route to overcome some of the PHB’s weaknesses, such as its slow crystallization, brittleness, modest thermal stability, and low melt strength is the addition of cellulose nanocrystals (CNCs) and the production of PHB/CNCs nanocomposites. Choosing the adequate processing technology for the fabrication of the PHB/CNCs nanocomposites and a suitable surface treatment for the CNCs are key factors in obtaining a good interfacial adhesion, superior thermal stability, and mechanical performances for the resulting nanocomposites. The information provided in this review related to the preparation routes, thermal, mechanical, and barrier properties of the PHB/CNCs nanocomposites may represent a starting point in finding new strategies to reduce the manufacturing costs or to design better technological solutions for the production of these materials at industrial scale. It is outlined in this review that the use of low-value biomass resources in the obtaining of both PHB and CNCs might be a safe track for a circular and bio-based economy. Undoubtedly, the PHB/CNCs nanocomposites will be an important part of a greener future in terms of successful replacement of the conventional plastic materials in many engineering and biomedical applications.

Biopackaging Potential Alternatives: Bioplastic Composites of Polyhydroxyalkanoates and Vegetal Fibers

Initiatives to reduce plastic waste are currently under development worldwide. As a part of it, the European Union and private and public organizations in several countries are designing and implementing regulations for single-use plastics. For example, by 2030, plastic packaging and food containers must be reusable or recyclable. In another approach, researchers are developing biopolymers using biodegradable thermoplastics, such as polyhydroxyalkanoates (PHAs), to replace fossil derivatives. However, their production capacity, high production costs, and poor mechanical properties hinder the usability of these biopolymers. To overcome these limitations, biomaterials reinforced with natural fibers are acquiring more relevance as the world of bioplastics production is increasing. This review presents an overview of PHA–vegetal fiber composites, the effects of the fiber type, and the production method’s impact on the mechanical, thermal, barrier properties, and biodegradability, all relevant for biopackaging. To acknowledge the behaviors and trends of the biomaterials reinforcement field, we searched for granted patents focusing on bio-packaging applications and gained insight into current industry developments and contributions.

Biosynthesized Poly(3-Hydroxybutyrate) on Coated Pineapple Leaf Fiber Papers for Biodegradable Packaging Application

This paper is aimed at investigating the usage of biosynthesized poly(3-hydroxybutyrate) (P(3-HB)) for a coating on pineapple leaf fiber paper (PLFP). For this purpose, (P(3-HB)) was produced by Rhodococcus pyridinivorans BSRT1-1, a highly potential P(3-HB) producing bacterium, with a weight-average molecular weight (M_w) of 6.07 × 10 ⁻⁵ g/mol. This biosynthesized P(3-HB) at 7.5% (w/v) was then coated on PLFP through the dip-coating technique with chloroform used as a solvent. The respective coated PLFP showed that P(3-HB) could be well coated all over on the PLFP surface as confirmed by scanning electron microscopy (SEM) and Fourier transform infrared (FTIR) spectroscopy. The brightness and mechanical properties of PLFP could be improved by coating with biosynthesized P(3-HB) in comparison to commercially available P(3-HB) and non-coated PLFP. Furthermore, coating of P(3-HB) significantly increased the water drop penetration time on the surface of PLFP and was similar to that of the commercial P(3-HB) with the same content. The results showed that all the coated PLPF samples can be degraded under the soil burial test conditions. We have demonstrated that the P(3-HB) coated PLFP paper has the ability to prevent water drop penetration and could undergo biodegradation. Taken together, the P(3-HB) coated PLFP can be applied as a promising biodegradable paper packaging.

Recent developments in the synthesis of poly(hydroxybutyrate) based biocomposites

Poly(hydroxybutyrate) (PHB) has become an attractive biomaterial in research and development for past few years. It is natural bio-based aliphatic polyester produced by many types of bacteria. Due to its biodegradable, biocompatible, and eco-friendly nature, PHB can be used in line with bioactive species. However, high production cost, thermal instability, and poor mechanical properties limit its desirable applications. So there is need to incorporate PHB with other materials or biopolymers for the development of some novel PHB based biocomposites for value addition. Many attempts have been employed to incorporate PHB with other biomaterials (or biopolymers) to develop sustainable biocomposites. In this review, some recent developments in the synthesis of PHB based biocomposites and their biomedical, packaging and tissue engineering applications have been focused. The development of biodegradable PHB based biocomposites with improved mechanical properties could be used to overcome its native limitations hence to open new possibilities for industrial applications.

Bio- and Fossil-Based Polymeric Blends and Nanocomposites for Packaging: Structure⁻Property Relationship

In the present review, the possibilities for blending of commodities and bio-based and/or biodegradable polymers for packaging purposes has been considered, limiting the analysis to this class of materials without considering blends where both components have a bio-based composition or origin. The production of blends with synthetic polymeric materials is among the strategies to modulate the main characteristics of biodegradable polymeric materials, altering disintegrability rates and decreasing the final cost of different products. Special emphasis has been given to blends functional behavior in the frame of packaging application (compostability, gas/water/light barrier properties, migration, antioxidant performance). In addition, to better analyze the presence of nanosized ingredients on the overall behavior of a nanocomposite system composed of synthetic polymers, combined with biodegradable and/or bio-based plastics, the nature and effect of the inclusion of bio-based nanofillers has been investigated.