Thermoplastic bacterial cellulose composite for sustainable packaging via extrusion blow molding
Novel thermoplastic bacterial cellulose (BC) derivative designed as reinforcement for polymer composites (PET, HDPE, PP) to produce rigid, sustainable packaging through extrusion blow molding. Offers a bio-based alternative to conventional plastics by eliminating wax, lignin, pectin, and hemicelluloses found in plant cellulose.
Overview
This project develops a thermoplastic bacterial cellulose (BC) derivative that can be blended with commodity polymers such as PET, HDPE, and PP to produce rigid packaging via extrusion blow molding. Unlike plant-based cellulose, bacterial cellulose is inherently nano-sized and free of wax, lignin, pectin, and hemicelluloses, giving it higher molecular weight and crystallinity. By chemically modifying BC with high molecular weight fatty acid chlorides, the team creates an amorphous thermoplastic material with a glass transition temperature comparable to PET, enabling melt blending and processing using standard plastics manufacturing equipment. The result is a bio-based composite pathway for sustainable, rigid packaging applications.
Technical specifications
- Bacterial cellulose source: Lab-synthesized BC, inherently nano-sized, higher molecular weight and crystallinity than plant cellulose, and free of wax, lignin, pectin, and hemicelluloses.
- Chemical modification: BC dissolved in ionic liquid, reacted with high molecular weight fatty acid chlorides in the presence of pyridine, then precipitated in methanol, filtered, and washed.
- Thermal behavior: Modified BC derivatives melt around 270–280 °C and exhibit a glass transition temperature (Tg) of approximately 133–136 °C, confirmed by DSC. Unmodified BC shows no Tg due to strong hydrogen bonding.
- Verification of modification: FTIR spectra show a new ester carbonyl peak at 1748–1720 cm⁻¹ (C=O ester stretching), confirming successful esterification of BC hydroxyl groups.
- Composite approach: Thermoplastic BC blended with PET (matching Tg), HDPE (Tm 135 °C), or PP (Tm 171 °C) to produce rigid packaging prototypes via extrusion blow molding, with miscibility assessed through hydrogen bond formation and a single Tg.
- Process parameters under study: Blend composition ratios, residence time, and screw speed for lab-scale melt mixing.
Technology readiness level
The technology is currently at an early-to-mid stage of development. Chemical modification of BC with fatty acid chlorides has been demonstrated in the lab, with successful verification by FTIR and DSC showing thermoplastic behavior and Tg values suitable for blending with PET. Future validation will focus on optimizing ionic liquid selection to improve thermal stability of BC derivatives, developing new BC grades with melting temperatures below 200 °C for HDPE and PP blending, and producing rigid packaging prototypes via extrusion blow molding. The project seeks industry partners for equipment access and support to scale prototype production. Estimated timeline for completion is approximately one year.
About Technological University of Shannon
Technological University of the Shannon (TUS) is a multi‑campus technological university spanning seven sites across Ireland’s Midlands and Midwest, combining applied research with strong industry engagement. Enterprise Ireland Technology Gateways on TUS campuses provide industry‑accessible labs, testbeds and prototyping with rapid routes to collaboration. A network of campus‑based enterprise and innovation centres offers incubation and co‑located collaboration space for startups and corporate R&D, while work placements are embedded across programmes and coordinated centrally for employers. Research is supported by national agencies such as Science Foundation Ireland, Enterprise Ireland and the Irish Research Council, alongside European funding programmes. A dedicated Knowledge Transfer and Commercialisation Office streamlines IP, licensing and spin‑out support.
delivered to your inbox.