Green and biodegradable coating for multilayer sustainable packaging

Overview

This research focuses on developing a fully biodegradable multilayer packaging solution for food applications. The approach combines paper substrates with biobased coatings made from modified starch or carbon biomass, polyhydroxyalkanoates (PHAs), and nanoclay fillers. The goal is to address growing consumer and regulatory demand for sustainable food packaging that delivers performance comparable to conventional plastics while being fully biodegradable and non-toxic.

Technical specifications

Key features:

• Paper substrate prepared from starch and carbon biomass, offering a low-cost, renewable base layer
• PHA-based coating providing improved water resistance and adhesion to the paper substrate
• Nanoclay fillers incorporated to enhance mechanical stiffness, tensile strength, and oxygen and water barrier properties
• Non-toxic formulation validated through antimicrobial assays, confirming food-safe applicability
• Characterization methods including tensile testing, thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and scanning electron microscopy (SEM)

Technology readiness level

The technology has been validated at the laboratory scale, with paper films already produced using carbon biomass with and without nanofillers. These films demonstrated good mechanical and thermal performance, enhanced stiffness and resistance with nanoparticle addition, and improved oxygen and water barrier properties. Future work includes developing chemically modified starch coatings, optimizing nanoparticle incorporation, conducting real-food packaging trials, performing pilot-scale testing, and completing life cycle and cost analyses to prepare the material for industrial adoption.