Recent Advances and Developments of Nanocellulose Reinforced Thermoplastic Starch Bionanocomposite: A Review

A review on nanocellulose in food packaging: A paradigm shift for enhanced mechanical strength and barrier performance.

The dependency on nonbiodegradable-based food packaging, increase in population growth, and persistent environmental problems are some of the driving forces in considering the development of biodegradable food packaging. This effort of green packaging has the potential to solve issues on plastic wastes through the combination of biodegradable composite-based food packaging with plant extracts, nanomaterials, or other types of polymer. Modified biodegradable materials have provided numerous alternatives for producing green packaging with mechanical strength, thermal stability, and barrier performance that are comparable to the conventional food packaging. To the best of our knowledge, the performance of nonbiodegradable and biodegradable composites as food packaging in terms of the above properties has not yet been reviewed. In this context, the capability of biodegradable polymers to substitute the nonbiodegradable polymers was emphasized to enhance the packaging biodegradation while retaining the mechanical strength, thermal stability, barrier properties, and antioxidant and antimicrobial or antibacterial activity. These are the ultimate goal in the food industry. This review will impart useful information on the properties of food packaging developed from different polymers and future outlook toward the development of green food packaging.

Rapid advancements in materials that offer the appropriate mechanical strength, barrier, and antimicrobial activity for food packaging are still confronted with significant challenges. In this study, a modest, environmentally friendly method was used to synthesize functionalized octakis(3-chloropropyl)octasilsesquioxane [fn-POSS] nanofiller. Composite films compared to the neat thermoplastic starch (TS) film, show improved thermal and mechanical properties. Tensile strength results improved from 7.8 MPa to 28.1 MPa (TS + 5.0 wt.% fn-POSS) with fn-POSS loading (neat TS). The barrier characteristics of TS/fn-POSS composites were increased by fn-POSS by offering penetrant molecules with a twisting pathway. Also, the rates of O2 and H2O transmission were decreased by 50.0 cc/m2/day and 48.1 g/m2/day in TS/fn-POSS composites. Based on an examination of its antimicrobial activity, the fn-POSS blended TS (TSP-5.0) film exhibits a favorable zone of inhibition against the bacterial pathogenic Staphylococcus aureus and Escherichia coli. The TS/fn-POSS (TSP-5.0) film lost 78.4% of its weight after 28 days in natural soil. New plastic materials used for packaging, especially food packaging, are typically not biodegradable, so the TS composite with 5.0 wt.% fn-POSS is therefore of definite interest. The incorporation of fn-POSS with TS composites can improve their characteristics, boost the use of nanoparticles in food packaging, and promote studies on biodegradable composites.

The use of composite materials has seen many new innovations for a large variety of applications. The area of reinforcement in composites is also rapidly evolving with many new discoveries, including the use of hybrid fibers, sustainable materials, and nanocellulose. In this review, studies on hybrid fiber reinforcement, the use of nanocellulose, the use of nanocellulose in hybrid forms, the use of nanocellulose with other nanomaterials, the applications of these materials, and finally, the challenges and opportunities (including safety issues) of their use are thoroughly discussed. This review will point out new prospects for the composite materials world, enabling the use of nano- and micron-sized materials together and creating value-added products at the industrial scale. Furthermore, the use of hybrid structures consisting of two different nano-materials creates many novel solutions for applications in electronics and sensors.

Effect of plant tannin and glycerol on thermoplastic starch: Mechanical, structural, antimicrobial and biodegradable properties

Innovations in food packaging systems will help meet the evolving needs of the market, such as consumer preference for "healthy" and high-quality food products and reduction of the negative environmental impacts of food packaging. Emerging concepts of active and intelligent packaging technologies provide numerous innovative solutions for prolonging shelf-life and improving the quality and safety of food products. There are also new approaches to improving the passive characteristics of food packaging, such as mechanical strength, barrier performance, and thermal stability. The development of sustainable or green packaging has the potential to reduce the environmental impacts of food packaging through the use of edible or biodegradable materials, plant extracts, and nanomaterials. Active, intelligent, and green packaging technologies can work synergistically to yield a multipurpose food-packaging system with no negative interactions between components, and this aim can be seen as the ultimate future goal for food packaging technology. This article reviews the principles of food packaging and recent developments in different types of food packaging technologies. Global patents and future research trends are also discussed.

Thermoplastic starch (TPS) blended with biodegradable polyesters such as polyhydroxybutyrate (PHB), polylactic acid (PLA), polybutylene succinate (PBS), and polycaprolactone (PCL) represents a promising route toward sustainable alternatives to petroleum-based plastics. TPS offers advantages related to abundance, low cost, and biodegradability, while polyesters provide improved mechanical strength, thermal stability, and barrier performance. However, the intrinsic incompatibility between hydrophilic TPS and hydrophobic polyesters typically leads to immiscible systems with poor interfacial adhesion and limited performance. This review critically examines recent advances in the development of TPS/polyester blends, with emphasis on compatibilization strategies based on chemical modification, natural and synthetic compatibilizers, bio-based additives, and reinforcing agents. Particular attention is given to the role of organic acids, essential oils, phenolic compounds, nanofillers, and natural reinforcements in controlling morphology, crystallinity, interfacial interactions, and thermal–mechanical behavior. In addition, the contribution of bioactive additives to antimicrobial and antioxidant functionality is discussed as an emerging multifunctional feature of some TPS/polyester systems. Finally, current limitations related to long-term stability, scalability, and life cycle assessment are highlighted, identifying key challenges and future research directions for the development of advanced biodegradable materials with tailored properties.

Food is fundamental to human survival, health, culture, and well-being. In response to the increasing demand for sustainable food preservation, chitosan (CS)-based electrospun nanofibers have emerged as promising materials due to their biodegradability, biocompatibility, and inherent antimicrobial properties. When combined with other biopolymers or bioactive compounds, CS-based nanofibers offer enhanced functionality for applications in food packaging, preservation, and additives. This review summarizes recent advances in the fabrication and performance of CS-polymer and CS-inorganic composite nanofibers, with a focus on their mechanical strength, thermal stability, barrier properties, and antimicrobial efficacy. The use of these nanofibers across a range of food categories-including vegetables, fruits, fresh-cut produce, dairy products, meat, seafood, and nuts-is examined. Beyond experimental approaches, the review also explores the growing role of computational simulations in predicting the mechanical strength, barrier performance, antimicrobial activity, and biodegradability of CS-based nanofibers. Key modeling techniques and simulation tools are summarized. Finally, current challenges and future research directions are discussed, underscoring the potential of CS-based electrospun nanofibers as sustainable and multifunctional solutions for modern food packaging. By integrating experimental advancements with computational insights, this review provides a comprehensive and forward-looking perspective on CS-based electrospun nanofibers for food packaging.

Poly[(butylene adipate)‐ co ‐terephthalate] (PBAT) is currently the most widely used and versatile petroleum‐based fully biodegradable polyester, drawing extensive attention from researchers. However, the high production cost of PBAT restricts its widespread application. Currently, incorporating fillers into PBAT materials is considered the most effective approach to reduce production costs, with thermoplastic starch recognized as the optimal filler for PBAT base materials. Nevertheless, the low mechanical strength of thermoplastic starch significantly compromises the performance of PBAT base materials. In this study, thermoplastic starch with higher mechanical strength was prepared by partially substituting commonly used glycerol with a higher molecular weight sorbitol as the plasticizer. The enhanced thermoplastic starch was then used as a filler for PBAT materials, leading to the fabrication of PBAT‐based blend films with high starch content. Mechanical property tests revealed a 52.2% and 65.3% increase of tensile strength in the transverse and longitudinal directions, respectively, when sorbitol partially replaced glycerol as the plasticizer for thermoplastic starch. Scanning electron microscopy results demonstrated improved dispersion of thermoplastic starch particles in PBAT when sorbitol and glycerol were used together. Meanwhile, the thermal performance and stability of PBAT were not significantly affected by the thermoplastic starch filling. © 2024 Society of Chemical Industry.

Starch extracted from the domestically cultivated Scala potato variety was explored as a renewable resource for the formulation of biodegradable thermoplastic starch (TPS)/polylactic acid (PLA) blends intended for environmentally friendly food packaging applications. The isolated starch underwent comprehensive physicochemical and structural characterization to assess its suitability for polymer processing. TPS derived from Scala starch was compounded with PLA, both with and without citric acid (CA) as a green compatibilizer to enhance phase compatibility. The resulting polymer blends were systematically analyzed using Fourier-transform infrared spectroscopy with attenuated total reflectance (FTIR–ATR), scanning electron microscopy (SEM), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), and X-ray diffraction (XRD) to evaluate thermal and structural properties. Mechanical performance, water vapor permeability (WVP), water absorption (WA), and biodegradability in soil over 56 days were also assessed. The incorporation of citric acid improved phase miscibility, leading to enhanced structural uniformity, thermal stability, mechanical strength, and barrier efficiency. Bio-degradation tests confirmed the environmental compatibility of the developed blends. Overall, the results demonstrate the potential of Scala-based TPS/PLA systems, particularly those modified with citric acid, as viable candidates for sustainable food packaging, while highlighting the importance of further formulation optimization to balance functional and biodegradative performance.

Among many other sustainable functional nanomaterials, nanocellulose is drawing increasing interest for use in environmental remediation technologies due to its numerous unique properties and functionalities. Nanocellulose is usually derived from the disintegration of naturally occurring polymers or produced by the action of bacteria. In this review, some invigorating perspectives on the challenges, future direction, and updates on the most relevant uses of nanocellulose in environmental remediation are discussed. The reported applications and properties of nanocellulose as an adsorbent, photocatalyst, flocculant, and membrane are reviewed in particular. However, additional effort will be required to implement and commercialize nanocellulose as a viable nanomaterial for remediation technologies. In this regard, the main challenges and limitations in working with nanocellulose-based materials are identified in an effort to improve the development and efficient use of nanocellulose in environmental remediation.

Zein exhibits excellent biodegradability, thermal stability, UV resistance, and water barrier properties, making it a promising candidate for food packaging applications. However, pure zein films suffer from brittleness and poor mechanical strength, which limit their practical use. In this study, a unique bilayer packaging film (ZP/P-C) was developed using a layer-by-layer solution casting technique, where hydrophobic zein was coated onto a polyvinyl alcohol and chitosan composite layer (P-C). Incorporating PEG400 into the zein layer improved the interfacial compatibility of the bilayer film, increasing its uniformity and toughness. The resulting bilayer films demonstrated enhanced mechanical properties, flexibility, and water vapor barrier performance. Specifically, the ZP7.5/P-C bilayer film showed an elongation at break of 68.74% and a modulus of elasticity of 187.19 MPa. It had a water vapor permeability of 6.60 × 10−11 g·m·m−2·s−1·Pa−1 and provided near-complete UV protection within the 200–350 nm range. Furthermore, an intelligent detection bilayer film was created by integrating anthocyanin extract into the zein layer. Adding anthocyanin improved the film’s antioxidant properties and allowed it to respond colorimetrically to total volatile basic nitrogen. The bilayer film ZPBA1.0/P-C displayed an excellent antioxidant activity (45.8%) and remarkable color change (ΔE = 20.2) in response to ammonia, effectively indicating shrimp spoilage in 48 h (ΔE > 10). This investigation spotlights the potential of zein-based bilayer films in active and intelligent food packaging, offering innovative strategies to improve food safety and extend the shelf life of perishable goods.

Innovative solutions and challenges to increase the use of Poly(3-hydroxybutyrate) in food packaging and disposables

Thermoplastic starch (TPS) suffers from its intrinsic low mechanical strength and high brittleness due to its strong hydrogen bonding and low chain mobility. The conventional way to crosslink the TPS film can improve the strength and stiffness of the films, but usually reduces the flexibility of the film, and increases its brittleness. In this study, the incorporation of the hybrid nanofiller [1 wt% nanocellulose (C) and 4 wt% nano bentonite (B)] into the TPS proved to improve greatly the films’ strength and flexibility. The hybrid nanofillers with ratio 4B:1C was incorporated into the crosslinked thermoplastic corn starch (CR-TPCS) film to increase the its flexibility and toughness and produced a high mechanical strength fully biodegradable film. Two different aqueous carboxylic acids: citric acid (CA) and tartaric acid (TA) with different pH values (2,4,6) as the green crosslinker were employed. Substantial increase of tensile strength (3.98 to 9.17 MPa), Young’s modulus (9.10 to 46.30 MPa) and elongation at break (55.2 to 135.7%) was observed for the CA- 4B1C/pH2 films compared to the CR-TPCS films. The melting temperature (Tm) of the CA-4B1C/pH2 improved compared to the TPCS/4B1C (un-crosslinked) film due to its crosslinking effect. Meanwhile, the CA-4B1C films exhibited the highest degree of substitution and di-esterification with the lowest swelling and water solubility properties due to the formation of a special “bridge” structure between the CA, nanocellulose and plasticizer. The “bridge” structure developed between the TPCS chains serves as the toughener to motivate higher chain stress relaxation and load endurance. The crosslinked “bridge structure” also proved to effectively reduce the retrogradation phenomenal in the TPCS films. This combination method of hybridization and crosslinking is an efficient, low cost, and environmentally friendly technique to overcome the low flexibility and brittleness problem of the TPS based packaging film.

Environmental concerns due to the wide use of plastic in food packaging have become one of the most significant challenges in the world. Consequently, the research in developing sustainable materials for food packaging has accelerated. Nanocellulose-based packaging is a biodegradable, renewable, and antimicrobial material with some competitive physicochemical characteristics when compared to plastic packaging. However, there has been insufficient research on a holistic discussion of the potentials and drawbacks of nanocellulose as well as its production, applications and disposal regarding sustainability. This study aims to evaluate the application of nanocellulose in food packaging. It gives an exhaustive overview of the essential aspects from the production to disposal of nanocellulose through a literature review. Then, a SWOT (Strengths, Weaknesses, Opportunities, Threats) analysis is used to evaluate the potential and drawbacks of applying nanocellulose in food packaging. It has been observed that the physicochemical properties of nanocellulose materials have the potential to be used in food packaging with fewer negative impacts on the environment. Furthermore, it supports the top tiers of the waste hierarchy and a circular economy. However, some challenges need to be addressed to ensure the safe and effective use of nanocellulose in food packaging, including high expenses, a lack of guidelines, and potential hazards to people and the environment. To eliminate these uncertainties, more studies need to be performed on applying nanocellulose in food packaging.