Biotechnological routes for the development of antimicrobial nano-metal based polyhydroxyalkanoates for active food packaging applications.

Abstract

The development of novel bio-based materials with antimicrobial properties for active packaging applications is a topic of significant interest. The current PhD thesis deals with the development of biotechnologically derived polyhydroxyalkanoates (PHAs) based on nanometals for antimicrobial active food packaging applications. Initially, silver nanoparticles (AgNPs) were produced by chemical reduction and stabilized in situ within unpurified poly(hydroxybutyrate-co-hydroxyvalerate), PHBV18 (18 mol% valerate) suspensions previously obtained from mixed microbial cultures. The stabilized AgNPs were subsequently used to develop PHAs-AgNPs nanocomposites following two different strategies: 1) a direct melt-blending process where the AgNPs were added to the PHBV3 (3% mol valerate) from a highly dispersed and distributed enriched masterbatch form and, 2) as an annealed electrospun coating of PHBV3/PHBV18/AgNPs over compression molded PHBV3. The implementation of both strategies resulted in active nanocomposites with strong antimicrobial activity against food-borne pathogens, being the electrospinning coating technique the most efficient one in reducing the bacterial and virus population, even at very low AgNPs loading (from 0.002 to 0.04% wt.). As an alternative route, an integrated bioprocess for the biological synthesis of AgNPs and polyhydroxybutyrate (PHB) from the fermentation process with Cupriavidus necator was also carried out. Interestingly, this work demonstrated for the first time, the inherent capacity of C. necator to reduce silver nitrate and produce AgNPs without the need for adding a reducing agent. The process was successfully optimized and scaled-up to a fully automated 10 liters bioreactor. Finally, because of the limitations of the use of AgNPs in food applications, antimicrobial PHAs films based on zinc oxide (ZnO) and copper oxide (CuO) nanoparticles were prepared according to the previously developed strategies but in this case, a melt-mixing process of preincorporated ZnO into unpurified PHBV18 fiber mats made by electrospinning was also carried out to stabilize the metal nanoparticles. The effect of ZnO nanoparticles morphology and the method of ZnO/CuO incorporation on the morphological, optical, thermal, mechanical and barrier properties of the resulting active films as well as their influence on the antimicrobial (bactericide and virucidal) performance were studied. Thus, this PhD thesis represents a significant step forward in the understanding of the antimicrobial efficacy of highly dispersed and distributed nanometals and highlights the suitability of the developed PHAs/nanometals materials for antimicrobial applications and in particular for antimicrobial active food packaging applications.