The Rise of Biodegradable Thin Films Across Industries

Plastic constitutes a significant portion of the inorganic solid waste generated daily in municipal solid waste (MSW). The substantial volume of plastic waste has severe environmental repercussions, contributing to soil pollution through landfilling, water pollution when dumped into oceans, and air pollution.

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Plastics make up approximately 5% - 12% of global waste generation, constituting around 20% - 30% of waste by weight. Alarmingly, about 60% of plastics end up as plastic waste (PW) in the environment.

Conventional plastics are typically produced from fossil fuels like petroleum and natural gas, whereas biodegradable plastics are sourced from renewable materials such as plant and microbial biomass.

These renewable biopolymers exhibit chemical and mechanical characteristics comparable to traditional plastics. Biodegradable thin films, a popular choice, contain additives that provide desirable properties and enable enzymes to break them down into simpler components that microorganisms can decompose.

Due to these advantageous characteristics, biodegradable thin films are widely chosen to promote net-zero emissions and significantly reduce plastic waste, thereby mitigating pollution.

An Introduction to Biodegradable Thin Films

Amid growing environmental concerns surrounding traditional plastic products, the world is turning to biodegradable thin film materials as an alternative. Biodegradable films and coatings, consisting of thin layers, are in high demand across various industries, particularly the food packaging sector.

These environmentally friendly packaging films and coatings primarily consist of proteins, polysaccharides, lipids, and antimicrobial ingredients. These coatings form a continuous thin layer, usually between 0.050 mm and 0.250 mm, which is deemed safe for consumption alongside food.

The materials used to produce these films originate from renewable biological sources, predominantly starch, cellulose, hemicellulose, proteins, gelatin, lipids, fibers, and similar resources.

The applications of biodegradable thin films require incorporating additives during manufacturing, such as antioxidants and antimicrobials, to enhance their structural strength and chemical stability.

In natural environments, microorganisms decompose biodegradable plastics into harmless elementary compounds under conditions such as soil, composting, anaerobic digestion, or water bodies. This results in the formation of by-products like carbon dioxide, water, and methane.

Compared to other degradation processes, biodegradation is significantly faster, and the by-products pose no harm to the environment.

Biodegradable thin films do not require special conditions or enzymes for breakdown and decompose alongside other organic waste. Once their operational time is complete and they are discarded, there is no need to separate these thin films from other wastes. This practice conserves time and money, making composting a sustainable and financially viable option.

Industries Leveraging Biodegradable Thin Films

Food packaging is a critical and intricate process, ensuring food quality according to standards while safeguarding it from germs and bacteria. Biodegradable films and coatings are the foremost products for this purpose, providing the most sustainable packaging solutions.

Fresh produce, such as fruits and vegetables, have higher respiration and transpiration rates, which can lead to microbial spoilage. Active thin films enable manufacturers to maintain unique in-package atmosphere modification.

This allows for the maintenance of a tailored environment for different types of fruits, ensuring their freshness. PLA-based films have proven effective in controlling respiration rates and moisture loss, particularly in fresh-cut pineapples.

In the dairy industry, there is a noticeable shift towards the use of biodegradable thin films. For instance, a prominent German dairy company, Dannon, introduced PLA packaging for its Activia yogurt in Germany.

PLA packaging has been adopted to store Danbo cheese in light and dark conditions. Additionally, antimicrobial biodegradable nisin films are utilized to inhibit yeast and mold growth, particularly in cheese products like mozzarella.

Biodegradable thin films show promise in addressing plastic debris accumulation and soil pollution. Active biodegradable films are considered an effective alternative to traditional plastic films for winter rapeseed production.

In a study involving summer maize, researchers utilized a combination of three biodegradable films. Results indicated an increase in soil temperature and water storage compared to traditional plastic film. The soil organic carbon content was approximately 15% higher in the group with biodegradable film, while these films also reduced nitrogenous gas release.

In addition to agriculture and packaging industries, biodegradable films are extensively used in the biomedical field. A prime example is chitosan-based biodegradable films in regenerative medicine, employed due to their biodegradability, porosity, and biomechanical compatibility.

Bone tissue engineering approaches using artificially fabricated grafts greatly benefit the regeneration of both autograft and allograft bone. These films support bone growth at attachment sites and help maintain structural integrity during in vivo tissue remodeling.

These biodegradable films are also extensively utilized for drug delivery in cancer treatment, revolutionizing the biomedical field.

Challenges in Biodegradable Thin Film Technology

While biodegradability offers sustainability advantages, several challenges must be efficiently addressed. Biopolymers utilized in biodegradable thin films require specialized industrial composting conditions for complete degradation, unlike backyard composting. This limitation arises due to the lack of accessibility in many regions.

The biodegradation rates of thin active films can vary significantly depending on the polymer type and environmental conditions, with reported timeframes ranging from less than 100 days to over a year.

Concerns have been raised about ecological toxicity from the accumulation of monomers, plasticizers, or nanoparticles released during fragmentation. Biodegradation may also release greenhouse gases like methane, potentially exacerbating climate change impacts.

The lack of composting infrastructure and waste collection systems in many areas poses a significant challenge for disposing of biodegradable plastics after use. These limitations threaten the commercialization of biodegradable thin films and strongly affect confidence in this technology.

Advancements in Biodegradable Thin Film Technology

Experts have begun using encapsulation technology to overcome the limitations of conventional biodegradable thin films and significantly enhance their physiochemical stability. Encapsulation involves enclosing or coating one substance within another material known as the wall material.

This innovative technology aims to protect sensitive bioactive natural compounds from damage, particularly under harsh conditions. However, stringent European regulations concerning food contact materials have limited the application of numerous encapsulated antimicrobial and antioxidant agents in release systems.

Addressing legislative restrictions and establishing a unified global organization would facilitate developing more precise and comprehensive regulations for materials in contact with food, ensuring specificity and accuracy in governing these materials and fostering innovation.

Researchers have incorporated biodegradable star-shaped PCL-PDLA plasticizers to achieve super-tough yet highly biodegradable blends of Poly(lactide-co-glycolide) (PLGA). These plasticizers were combined with PLGA to produce transparent thin films. A mere 0.5 wt% addition of star-shaped PCL-b-PDLA increased the elongation at break of the PLGA blend to approximately 248%, without compromising its mechanical strength or modulus.

The morphology of the PLGA blends revealed a robust cross-linked network between the PLLA and PDLA segments, effectively enhancing interfacial adhesion.

The Future of Biodegradable Thin Films

Various industries are now exploring biodegradable thin films due to their numerous advantages. The advancement of new biodegradable polymers necessitates simplicity, cost-effectiveness, and recyclability wherever feasible, presenting significant employment opportunities. The emergence of new hybrid systems is anticipated as these novel biodegradable polymers exhibit crucial properties.

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References and Further Reading

[1] Paletta, A., et al. Barriers and challenges to plastics valorisation in the context of a circular economy: Case studies from Italy. Journal of Cleaner Production. doi.org/10//j.jclepro..

[2] Zhang, F., et al. Current technologies for plastic waste treatment: A review. Journal of Cleaner Production. doi.org/10//j.jclepro..

[3] Dirpan, A., et al. A Review on Biopolymer-Based Biodegradable Film for Food Packaging: Trends over the Last Decade and Future Research. Polymers. doi.org/10//polym

[4] Gupta, V., et al. A Comprehensive Review of Biodegradable Polymer-Based Films and Coatings and Their Food Packaging Applications. Materials. doi.org/10//ma

[5] Edaes, F., et al. Conventional Plastics' Harmful Effects and Biological and Molecular Strategies for Biodegradable Plastics' Production. Current Biotechnology. doi.org/10//

[6] Guo, C., et al. Progress in the Degradability of Biodegradable Film Materials for Packaging. Membranes. doi.org/10//membranes

[7] Cheng, J., et al. Applications of biodegradable materials in food packaging: A review. Alexandria Engineering Journal. doi.org/10//j.aej..01.080

[8] Sun, Y., et al. Past, present, and future perspectives of biodegradable films for soil: A 30-year systematic review. Frontiers in Bioengineering and Biotechnology. doi.org/10//fbioe..

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