Vapor Barrier Research Articles

Improved sustained-release properties of ginger essential oil in a Pickering emulsion system incorporated in sodium alginate film and delayed postharvest senescence of mango fruits

The insufficient water vapor barrier and mechanical capacity of sodium alginate (SA) film limited its application in fruit preservation. Herein, cellulose nanocrystals (CNCs) were used to stabilize Pickering emulsion. Then, we prepared SA composite films. Ginger essential oil (GEO) was loaded as antimicrobials and antioxidants. Finally, the application on mangos were investigated. Compared to coarse emulsion, Pickering emulsion and its film-formation-solution showed more stable system and larger droplet size. The emulsion significantly changed the properties of SA film. Specifically, CNCs improved the thermal, tensile, and barrier properties of the film and GEO enhanced the ultraviolet-visible light barrier capacity. Additionally, the SA/CNC film possessed a homogeneous micromorphology which had a sustained-release effect on GEO, thus maintaining high postharvest quality and long-term bioavailability for mangos. In conclusion, the film prepared via Pickering emulsion showed satisfactory properties which had great potential in fruit preservation.

Internal moisture barrier layer for improving high-humidity reliability of miniature light emitting diode die without encapsulation.

Atomic layer deposited Al2O3 films are incorporated into miniature light emitting diodes (mini-LEDs) as an internal moisture barrier layer. The experimental results show that the water vapor transmission rate reaches ≤10-4 g/m2/day when the Al2O3 thickness is ≥40 nm. The mini-LED with a 40 nm-thick Al2O3 layer shows negligible degradation after 1000 h of 85°C/85% relative humidity testing, whereas the device without an Al2O3 layer fails after only 500 h due to delamination occurring at the GaN surface. Current-voltage characteristics of the device without an Al2O3 moisture barrier layer indicate an increase in series resistance and ideality factor. This study provides a simple, light-weighting method to have a satisfactory encapsulation function for miniature LEDs.

Development of functional active films from blend of gelatin with crude orange juice pomace pectin: Test for packaging of virgin olive oil

AbstractThe food packaging sector is focused on developing innovative materials to enhance food safety and quality while reducing environmental impact. Accordingly, this study aimed to develop packaging based on bovine gelatin (G) blended with crude sweet orange juice pomace pectin (SOPP) at different ratios (G/SOPP = 85/15, 65/35, 50/50, w/w). The obtained crude SOPP was highly methylated and exhibited antioxidant and antibacterial properties due to the presence of galacturonic acid (<70%) and phenolic compounds (58.2 ± 0.8 mg/g SOPP). High‐performance liquid chromatography with diode array detection analysis revealed the presence of hesperidin, catechin, and naringin as major phenolic compounds in SOPP. Further, the incorporation of this latter improved gelatin‐based packaging structural homogeneity, opacity, water vapour barrier features, glass transition temperature and tensile strength. G‐SOPP (50/50) film showed efficient antibacterial activity against Escherichia coli and Bacillus subtilis and high antioxidant potential reaching values of 0.7, 48.7%, 76.7% and 68.9% for reducing power, β‐carotene bleaching inhibition, DPPH (2,2‐diphenyl‐1‐picrylhydrazyl) and ABTS+ (2,2′‐azinobis‐[3‐ethylbenzothiazoline‐6‐sulphonic acid]) radicals scavenging activities, respectively. Another interesting finding is that the combination of G and SOPP reduced the oil solubility of G‐SOPP films suggesting great physical integrity of the film over 63 days. The polyphenol content released from G‐SOPP blend film in a fatty simulant increased as SOPP content of films was increased. G‐SOPP (50/50) film, designed as a pouch, delays the photooxidation process of virgin olive oil over 63 days of storage time, without altering its organoleptic properties. Overall, these outstanding results highlighted the potential use of gelatin–pectin blend films for active packaging of oils and lipid‐based foods.

Converting and its effects on barrier properties of coated packaging materials: A Review

Considerable research is ongoing, examining opportunities for substituting plastic packaging with more sustainable alternatives, and some encouraging results have been achieved. Coated paper and paperboard demonstrate promising performance; however, several serious drawbacks still need to be overcome. Recent research in this area is reviewed in the current work, including mechanical and machinery aspects of paperboard converting, as well as barrier properties of coated materials before and after processing. The main objective of the study was to establish how coated paperboard behaves during converting operations and investigate what changes in its properties occur, considering not only the convertibility of the material as a whole but also effects on substrates and coatings. The results of the literature review show that creasing, folding, and the presence of forming stresses severely damage barrier and pigment coatings even if the paperboard-based product is reported as having good oxygen and water vapour barrier or oil resistance after production. Thus far, most materials cannot fully match the performance of plastic packaging materials due to a noticeable reduction in barrier properties after converting. The work presents factors linking the convertibility of coated materials and their subsequent barrier properties as valuable knowledge to support future development of sustainable materials.

Preparation of PVA/Tremella polysaccharide and soy protein isolate complex/ε-polylysine active membrane and its application in blueberry preservation

This study aimed to investigate the physicochemical properties, antioxidant and antibacterial activities of Tremella polysaccharides combined with soybean protein isolate (TFP-SPI), natural antibacterial agent ε-polylysine (PL) and polyvinyl alcohol (PVA) hybrid membrane and its applicability in the blueberry preservation. In this study, TFP-SPI was successfully prepared, and it was mixed with PL and PVA to prepare nanofiber membranes. FTIR results showed that TFP-SPI had hydrogen bond interaction. The physicochemical properties showed that the incorporation of TFP-SPI improved the hydrophilicity and mechanical properties of the membrane, providing the best water vapor barrier performance. In vitro antioxidant experiments showed that PVA/TFP-SPI/PL membranes possessed antioxidant capacity. In vitro antibacterial experiments showed that PVA/TFP-SPI/PL membranes had antibacterial activity, especially against Staphylococcus aureus. The results of fruit preservation showed that PVA/TFP-SPI/PL membrane could effectively extend the shelf life of blueberries and maintain good quality. Therefore, PVA/TFP-SPI/PL membrane is a potential active packaging material with promising application prospects.

Biodegradable Blown Film Composites from Bioplastic and Talc: Effect of Uniaxial Stretching on Mechanical and Barrier Properties

AbstractAs public awareness about climate change grows, there is an increase in the research on bioplastic packaging films. This is the first‐ever scientific report on uniaxially stretched biobased‐polybutylene succinate‐co‐adipate (BioPBSA) and talc (15 and 25 wt%) based blown film composites at different stretch ratios (SR). The water vapor barrier properties of BioPBSA+25%Talc film at SR 4 shows an improvement of 40% compared to its unstretched counterpart, while an overall improvement of 48% is observed compared to the unstretched BioPBSA film. The successful dispersion of talc in the BioPBSA matrix, the orientation of talc filler during stretching, and the polymer chains orientation are responsible for such improvement. Additionally, XRD analysis shows that during uniaxial stretching, the crystallinity of the films increases by up to 26% as a result of strain‐induced crystallization, with BioPBSA+25%Talc at SR 4 having the highest crystallinity (≈75%). Furthermore, the inclusion of 25% talc in BioPBSA considerably enhances the tensile modulus by 246% compared to its unstretched counterpart. Hence biodegradable films with balanced barrier and tensile properties may be promising alternatives to petroleum‐based plastic materials used in flexible packaging applications.

Ultra-thin parylene-aluminium hybrid coatings on nanocellulose films to resist water sensitivity

Non-sustainable single-use plastics used for food packaging needs to be phased out. Films made from cellulose nanofibrils (CNFs) are suitable candidates for biodegradable and recyclable packaging materials as they exhibit good mechanical properties, excellent oxygen barrier properties and high transparency. Yet, their poor water vapour barrier properties have been a major hindrance in their commercialisation. Here, we describe the preparation of 25 μm thick CNF films with significantly improved water vapour barrier properties after deposition of ultrathin polymeric and metallic coatings, parylene C and aluminium, respectively. When first adding a 40 nm aluminium layer followed by an 80 nm parylene layer, i.e. with a combined thickness of less than one percent of the CNF film, a water vapour transmission rate of 2.8 g m−2 d−1 was achieved at 38 °C and 90 % RH, surpassing a 25 μm polypropylene film (4–12 g m−2 d−1). This is an improvement of more than 700 times compared to uncoated CNF films, under some of the harshest possible conditions a packaging material will need to endure in commercial use. The layers showed a good and even coverage, as assessed by atomic force microscopy, and the parylene-coated surfaces were hydrophobic with a contact angle of 110°, providing good water repellency.

Performance of a Chemical Heat Blanket in Dry, Damp, and Wet Conditions Inside a Mountain Rescue Hypothermia Wrap

Casualties with accidental hypothermia are evacuated using multilayer wraps, typically including a chemical heat blanket (CHB), a vapor barrier, and an insulating outer bag. We investigated CHB performance against dry, damp, and wet fabric, in a multilayer wrap, in response to a case report indicating diminished performance when wet. We wrapped a torso manikin in a base layer, CHB, vapor barrier, casualty bag, and vacuum mattress, recording CHB panel temperatures at intervals of up to 7 h. Experimental conditions were dry, damp, and wet clothing, with 2 blankets tested in each condition. We subsequently used a forward-looking infrared camera to assess whether the panels heated evenly and heat flux sensors to quantify heat transfer across 2 dry, 1 damp, and 1 wet fleece under CHB panels. Chemical heat blankets maintained heat output for >7 h inside the wraps. Median (IQR) panel steady state temperatures were 52°C (39-56°C) against dry fleece, 41°C (36-45°C) against damp fleece, and 30°C (29-33°C) against wet fleece. Peak panel temperature was 67°C. The heat flux results indicated that CHBs generated similar quantities of heat in dry and damp conditions, as the lower temperatures were compensated by more efficient transfer of heat across the moist clothing layer. Chemical heat blanket heat output was diminished in wet conditions. Rescuers should cut off saturated clothing in a protected environment before wrapping casualties, but damp clothing need not be removed. Because of the high peak temperatures recorded on the surfaces of CHBs, they should not be placed directly against skin, and compression straps should not be placed directly over CHBs.

Enhanced water vapor barrier and gas barrier properties of transparent poly(butylene adipate‑co‑terephthalate)/poly(lactic acid)/hexagonal boron nitride nanosheets composite films

The water vapor barrier and gas barrier properties are very important factors for biodegradable packaging films. Herein, nano-sized hexagonal boron nitride nanosheets (hBNNSs) were facilely exfoliated, and novel transparent poly(butylene adipate-co-butylene terephthalate) (PBAT)/poly(lactic acid) (PLA) films incorporated with hBNNS were developed. Compared to those properties of neat PBAT/PLA film, the water vapor barrier of PBAT/PLA/hBNNSs films was greatly enhanced by 67%. Meanwhile, the oxygen permeability (OP) and carbon dioxide permeability (CO2P) of CS/hBNNSs films are significantly lowered by 65% and 93%, respectively. In addition, their thermal stabilities and mechanical property are also enhanced.

Composite material with enhanced recyclability as encapsulant for photovoltaic modules

Encapsulation of photovoltaic cells was carried out using a transparent glass fiber reinforced composite with enhanced chemical recyclability based on a matrix of an epoxy resin containing cleavable functional groups. The current-voltage curves showed a decrease of 6.3% on the short-circuit current (Isc) after encapsulation of the cell, lower than the one observed for the reference non-recyclable standard epoxy composite. Its performance stability under thermal cycling, ultraviolet (UV), and damp-heat exposure was evaluated and compared with the one of the reference standard epoxy. Both resins showed good stability performance under UV exposure and thermal cycling accelerated aging. Moreover, a power loss below the 5% allowed by the photovoltaic standard was observed for the recyclable resin after 1000 h of damp-heat exposure, even the pronounced loss of 4.7% in power remains a concern. Regarding the recyclability, the composite was dissolved in acetic acid dissolution and glass fiber fabrics were successfully recovered. A new module was manufactured with these fabrics, showing this time a loss of 12% in Isc comparing with the non-encapsulated cell. Further work will consider improving the moisture barrier properties of the composite, and adjusting the recycling conditions to allow component recovery valid for new modules.

Development of Indicator Film Based on Cassava Starch-Chitosan Incorporated with Red Dragon Fruit Peel Anthocyanins-Gambier Catechins to Detect Banana Ripeness.

Banana ripeness is generally determined based on physical attributes, such as skin color; however, it is considered subjective because it depends on individual factors and lighting conditions. In addition, improper handling can cause mechanical damage to the fruit. Intelligent packaging in the form of indicator film incorporated with anthocyanins from red dragon fruit peel has been applied for shrimp freshness detection; however, this film has low color stability during storage, necessitating the addition of gambier catechins as a co-pigment to increase anthocyanin stability. Nevertheless, the characteristics of films that contain gambier catechins and their applications to bananas have not been studied yet; therefore, this study aims to develop and characterize indicator films that were incorporated with red dragon fruit peel anthocyanins and gambier catechins to detect banana ripeness. In this study, the indicator films were made via solvent casting. The films were characterized for their structural, mechanical, and physicochemical properties, and then applied to banana packaging. The results show that the film incorporated with anthocyanins and catechins in a ratio of 1:40 (w/w) resulted in better color stability, mechanical properties, light and water vapor barrier ability, and antioxidant activity. The application of the indicator films to banana packaging resulted in a change in color on the third day of storage. It can be concluded that these films could potentially be used as an indicator to monitor banana ripeness.

Alginate/guacamole edible films as moisture barrier layers in multicomponent foods

AbstractIn multicomponent foods having both moist and dry components (e.g., pizzas and tacos), moisture migration between components causes undesirable texture changes (e.g., loss of crispiness of the dry component). In this study, different proportions of alginate (film matrix), guacamole (hydrophobic component with sensory appeal), and glycerol (plasticizer) were combined to form edible films to be used as a moisture barrier between moist and dry components of multicomponent foods. Alginate was the component that most contributed to increase the film strength and to reduce its water vapor permeability (WVP). Guacamole, due to the presence of avocado lipids, enhanced the film hydrophobicity, although not having decreased the WVP (as expected), since it promoted discontinuities in the alginate structure. The film with the lowest WVP (containing an alginate/guacamole/glycerol dry mass ratio of 25/60/15) was inserted between nachos and tomato sauce, being able to reduce the crispiness loss of nachos during a 50‐min storage.

Fabrication of polyvinyl alcohol-starch controlled release active film incorporated with 2-hydroxypropyl-β-cyclodextrin/lemongrass oil emulsion for large yellow croaker (Pseudosciaena crocea) preservation

Polyvinyl alcohol-starch (PVA/ST) active films incorporated with lemongrass oil (LMO) or 2-hydroxypropyl-β-cyclodextrin, and LMO (HP-β-CD/LMO) emulsion were developed in the present work. The effects of LMO or HP-β-CD/LMO emulsion on the properties of films, and their application in large yellow croaker preservation were investigated. The average particle size and the encapsulation efficiency of the HP-β-CD/LMO emulsion were 150.07 nm and 81.32%, respectively. The scanning electron microscopy (SEM) results revealed that HP-β-CD improved the compatibility between PVA and starch, and LMO was well embedded in HP-β-CD. The incorporation of LMO or HP-β-CD/LMO enhanced the water vapour barrier property and flexibility of the film while weakening its mechanical strength. The oxygen barrier property of the film was weakened by the incorporation of LMO and strengthened by HP-β-CD/LMO. The film incorporated with HP-β-CD/LMO exhibited a little weaker antioxidant and antibacterial activities than the film containing LMO owing to their release property. The existence of HP-β-CD postponed the release of LMO from the film into food simulant (10% ethanol). The preservation results demonstrated that the film containing LMO or HP-β-CD/LMO efficiently inhibited the growth of microorganisms and lipid oxidation of fish; and delayed the decomposition of protein and freshness reduction of large yellow croaker. Additionally, the film added with HP-β-CD/LMO exhibited the best protection for fish quality. In other words, the film with the proper release property of active agents contributed to the preservation of aquatic products.

Effects of Stearic Acid and Zein Incorporation on Refined Kappa Carrageenan-Based Composite Edible Film Properties

Incorporating hydrophobic materials into a polysaccharide-based film to form a composite edible film has been considered an effective way to strengthen the film properties, especially the water vapor resistance. Fatty acids, such as stearic acid, with long-chain and straight structures, exhibit strong hydrophobic performance to prevent water vapor diffusion through the film surface. Meanwhile, zein has been revealed as an encouraging material due to its compactness, less allergic, and gas barrier properties. The investigation of kappa-carrageenan/zein/stearic acid-based green composite edible film has been limited. Thus, this study aims to examine the effect of increasing stearic acid and zein concentrations on improving the moisture barrier and mechanical properties of kappa carrageenan-based composite edible film. Different concentrations of stearic acid (5, 10, and 15% w/w carrageenan) and zein (2.5, 5, and 7.5% w/w carrageenan) were applied to the composite edible film prepared using the solution casting method. The fabricated films have a thickness of 0.092–0.122 mm. The results indicated that increasing the concentration of stearic acid enhances the water vapor barrier and tensile strength of the edible film (p < 0.05). However, the increased zein concentration slightly weakened the water vapor barrier properties. Then, the elongation of the manufactured films was quite improved by the increment of stearic acid proportion, but neither by the increment of zein proportion nor the combination of these two substances. However, the incorporation of stearic acid and zein into refined-kappa carrageenan-based film remarkably improved the tensile strength, elongation, and water vapor barrier properties by 12–18%, 23–27%, and 43–44%, respectively, in comparison to the neat film. Based on the analysis result, the manufactured film which consists of 10% stearic acid and 2.5% zein is considered as the best film formula. This study, therefore, revealed the potentiality of stearic acid enforcement in food packaging applications.

Water Vapour Resistance of Ceiling Paints—Implications for the Use of Smart Vapour Barriers in Compact Wooden Roofs

Smart vapour barriers enable building envelopes to dry toward the interior side. This property can be used in compact wooden roofs to create more slender structures by placing the wooden load-bearing elements inside the insulation layer. There is, however, some concern that the ceiling assembly on the interior side may inhibit inward drying by trapping moisture between the vapour barrier and the ceiling boards. This article examined the water vapour resistance of gypsum boards painted with two, four, and six layers of typical ceiling paints. WUFI® 2D simulations were conducted to assess the risk of mould growth in compact wooden roofs with painted board ceilings. It was found that a painted ceiling board may exhibit an equivalent stagnant air layer thickness (sd value) between 0.074 m for two layers of the most vapour-open paint and 0.53 m for six layers of the least vapour-open. For an unpainted board, the sd value was measured to be 0.071 m. The difference was not found to make a substantial impact on the drying of a typical compact wooden roof. The application of paint may cause the assembly to dry at a slightly slower rate but was not found to present a notably higher risk of mould growth, even under unfavourable conditions.

Enhancement of the mechanical properties and water barrier properties of thermoplastic starch nanocomposite films by chitin nanofibers: Biodegradable coating for extending banana shelf life

Starch-based films have limited applications due to their hydrophilicity and poor mechanical performance. Herein, thermoplastic starch (TPS) nanocomposite films with chitin nanofibers (ChNFs) extracted from shrimp-shell waste were successfully fabricated using a solvent casting method. We investigated the effects of the ChNF loadings on the physical, mechanical, and water vapor barrier properties of the nanocomposite films. The well-dispersed ChNFs within the soft matrix associated with the formation of interfacial bonding between ChNFs and starch facilitated the efficient stress transfer from the soft matrix to the stiff ChNFs. Additionally, the presence of ChNFs created tortuous pathways within the films, which could impede the diffusion of water molecules. This resulted in a significant improvement in the mechanical properties, wettability, water resistance, and water vapor barrier properties of the nanocomposites. Compared to the results obtained from the neat TPS films, the TPS nanocomposites reinforced with ChNFs exhibited a 300% higher tensile stress, a 603% Young's modulus, and a considerable increase in the water contact angle, shifting from 86.2° to 98.6°. Furthermore, the ChNF-reinforced nanocomposite films showed no fragmentation after being soaked in water for 12 h under vigorous stirring, whereas the neat TPS films disintegrated under the same conditions. Interestingly, we found that coating a suspension of TPS and ChNFs on bananas effectively delayed their aging, preventing the color change from green to yellow. This promising result demonstrates the potential of the developed coating to extend the shelf life of fresh food produce, reducing food waste and the reliance on single-use petroleum-based packaging.

Heat sealable regenerated cellulose films enabled by zein coating for sustainable food packaging

The development of green packaging materials is requested due to the growing concerns about plastic waste. As the most abundant natural polymer on earth, cellulose can be dissolved and regenerated to make transparent films. However, cellulose is not a thermoplastic, so cellulose films are usually sealed by an adhesive for packaging applications. Herein, this study aimed to endow regenerated cellulose (RC) films with heat sealability by coating a layer of zein, and the mechanical and barrier properties of the composite cellulose/zein films were characterized. The results revealed that, with a thin zein coating, all the composite films were able to be sealed by a tabletop impulse sealer without the need for high temperature or high pressure and showed larger tensile strain and better water vapor and oxygen barrier properties compared to the RC films. Moreover, it was worth noting that the blueberries packed in the heat-sealed cellulose/zein bags were protected from oxidation and spoilage during a 12-day storage period and were comparable to the ones packed by Ziploc®. Thus, this work demonstrates a facile way to fabricate cellulose-based packaging materials that are heat sealable and have potential applications in sustainable food packaging.

Effect of waste Dunaliella tertiolecta biomass ethanolic extract and turmeric essential oil on properties of guar gum-based active films

The presented work focuses on the development of guar gum-based active films infused with two bio-fillers such as crude algae ethanolic extract (CAEE) and turmeric essential oil (TEO). Besides, the waste biomass of Dunaliella tertiolecta (after oil extraction) was utilized in this study to obtain CAEE. The CAEE was extracted using ultrasound-assisted technology. The influence of varying concentrations of TEO (0.5%, 1%, and 2%) at fixed CAEE concentration on the film properties including mechanical, morphological, optical, thermal, water vapor barrier, antioxidant, and antimicrobial activity was investigated. The rheological properties of the film-forming solution were also analyzed. The incorporation of CAEE and TEO improved elongation at the break value of films by ∼18% and reduced the water vapor transmission rate by ∼35%. The results of thermal stability indicated that the active films were stable at the temperature range of 25–80 °C. The increasing surface roughness, hydrophobicity, and reduction in transparency (∼32%) with UV-light blocking properties were exhibited by the developed films with increasing TEO concentration. The non-Newtonian pseudoplastic behavior was found in film-forming solutions. Furthermore, the developed active films demonstrated superior (p < 0.05) antioxidant properties and antimicrobial behavior against two known food pathogens namely, Escherichia coli and Staphylococcus aureus. Therefore, the findings of the study stipulated the synergistic effect of CAEE and TEO incorporated guar gum-based films as excellent active films. Moreover, this study could contribute to the utilization of biowaste and the development of sustainable active packaging materials that would enhance food quality and safety.

Development and characterization of cinnamon essential oil incorporated active, printable and heat sealable cellulose nanofiber reinforced hydroxypropyl methylcellulose films

Cellulose nanofiber (CNF) reinforced hydroxypropyl methylcellulose (HPMC) films were incorporated with antioxidant cinnamon essential oil (CEO) to develop active, printable, and heat-sealable films. CEO was carried into the films via three types of active systems: β-cyclodextrin (β-CD) encapsulation, cellulose nanocrystal (CNC) Pickering emulsion (CNC-P), or the combination thereof (CNC-P/β-CD). The films were characterized for their mechanical, physicochemical, structural, thermal, and optical properties along with CEO release, printability, and heat seal strength. The Control film (without active CEO) and CNC-P film showed the highest transparency, 17.02% and 18.17%/mm, respectively, followed by the CNC-P/β-CD (12.86%/mm) and β-CD (11.68%/mm) films. A significant difference (P < 0.05) in water vapor permeability (WVP) was observed between the Control film stored at 33% RH (72.01 g mm/m2 d kPa) and 53% RH (54.45 g mm/m2 d kPa) whereas no difference in WVP for β-CD, CNC-P, and CNC-P/β-CD films under RH range of 33–84% (P > 0.05). The presence of active CEO in the films enhanced the moisture barrier and stability of films without influencing the mechanical and thermal properties of the films. The CEO incorporated films via both CNC Pickering emulsion and β-CD encapsulation prolonged the release of CEO. All CEO incorporated films were printable by inkjet and stamp inks and showed good heat seal strength (∼61–73 N/m). This study provided new strategies to develop cellulose-based active films with extended antioxidant function and sealable and printable properties to replace single-use plastic packaging for various food, especially high-fat food items.

Biodegradable blown film composite from poly (butylene adipate-co-terephthalate) and talc: Effect of uniaxial stretching on mechanical and barrier properties

This research focuses on improving the oxygen and water vapour barrier properties of blown PBAT films after adding talc particles (15 and 25 wt%) followed by uniaxial stretching in the machine direction. DSC analysis revealed that the addition of talc enhanced %crystallinity by ∼42 and ∼125% at stretch ratios 5.5 and 6.0, respectively, compared to unstretched neat PBAT films, due to the dispersion and platelets morphology of talc particles, followed by uniaxial orientation of polymer chains. This significantly impacted the mechanical properties of PBAT as elastic modulus gained by ∼1939 and ∼2486% for the stretched composite films containing 15 and 25 wt% talc, respectively, over unstretched neat PBAT. The water vapour barrier of the stretched composite films was improved by ∼61 and ∼62% after adding 15 and 25 wt% talc particles, respectively, compared to PBAT due to its increased %crystallinity and can be a sustainable alternative to single-use plastics in flexible packaging.