Biobased polymer blend coatings and films for compostable packaging applications

Overview

This research platform focuses on developing advanced compostable coatings and films by engineering the chemistry, morphology, and blending of diverse biobased polymers. The work expands beyond conventional PLA to incorporate PBS (polybutylene succinate), PHA (polyhydroxyalkanoates), PBAT (polybutylene adipate terephthalate), and their copolymer blends. The goal is to overcome the key performance and cost barriers that currently limit widespread adoption of biobased packaging in food service, consumer goods, and industrial applications.

The platform addresses critical industry requirements including mechanical strength, gas and moisture barrier properties, optical clarity, food-contact safety, and compatibility with both home and industrial composting facilities. By tailoring polymer interactions at the molecular level, the approach aims to deliver packaging materials that compete with conventional plastics on performance while remaining cost-competitive and fully compostable.

Technical specifications

Core approach:

• Systematic evaluation of biobased polymer blends beyond PLA, including PBS, PHA, PBAT, and copolymer combinations
• Melt-extrusion compounding to fabricate films and coatings at varied copolymer concentrations
• Molecular interaction analysis within amorphous and crystalline regions using FTIR and Raman spectroscopy, differential scanning calorimetry, dynamic mechanical analysis, and dynamic melt rheology
• Thermogravimetric analysis for thermal stability and degradation kinetics characterization
• Surface free energy measurement via contact angle hysteresis under ambient conditions
• Quantification of industry-relevant barrier properties including water vapor and oxygen permeation
• Mechanical property evaluation across blend compositions

Target properties:

• Enhanced mechanical performance suitable for flexible films and rigid packaging
• Improved gas and moisture barrier characteristics for food packaging applications
• Optical transparency where required for consumer-facing applications
• Compostability in both home and industrial composting environments
• Cost competitiveness with conventional petroleum-based packaging alternatives

Technology readiness level

This research builds on a strong foundation of previously published and patented work from the lab group demonstrating performance and cost-effective strategies for blended biobased polymer systems. Prior publications include work on biobased coatings using specialty oils, PBS coatings for paperboard convenience food packaging, and nanoparticle-enabled transparent UV-blocking coatings. The team has an active U.S. patent application related to bio-based coatings and adhesives.

Current and future validation efforts will fabricate biopolymer blend films and coatings, then systematically characterize molecular interactions, thermal behavior, surface properties, barrier performance, and mechanical properties. The research is positioned to advance blended biobased polymer systems toward commercial packaging applications through continued optimization of composition-property relationships.