Within this paper, we are dealing with a mixture of thermoplastic polymer that is filled with inorganic fillers at high concentrations up to 60 vol.%. A high number of particles in the compound can substantially change the rheological behaviour of the composite and can lead to problems during processing in the molten state. The rheological behaviour of highly filled materials is complex and influenced by many interrelated factors. In the present investigation, we considered four different spherical materials: steel, aluminium alloy, titanium alloy and glass. Particles with similar particle size distribution were mixed with a binder system at different filling grades (30–60 vol.%). We showed that the rheological behaviour of highly filled materials is significantly dependent on the chemical interactions between the filler and matrix material. Moreover, it was shown that the changes of the particle shape and size during processing lead to unexpected rheological behaviour of composite materials as it was observed in the composites filled with glass beads that broke at high contents during processing.

Poly(lactic acid) (PLA) nanocomposites with antimicrobial fillers have been increasingly explored as food packaging materials that are made of a biobased matrix and can minimize food loss due to spoilage. Some of the most commonly studied fillers are zinc oxide (ZnO), titanium dioxide (TiO₂), and silver nanoparticles (AgNPs). In this work, nanocomposites with 1 wt.% of each filler were prepared by melt mixing. An extensive study of thermally stimulated processes such as crystallization, nucleation, degradation, and their kinetics was carried out using Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). In detail, non-isothermal cold crystallization studies were performed with DSC and polarized light microscopy (PLM), and kinetics were analyzed with multiple equations. The activation energy of the non-isothermal cold crystallization was calculated with the methods of Kissinger and Friedman. The latter was used to also determine the Hoffman–Lauritzen parameters (K_g and U*) by applying the Vyazovkin method. Additionally, effective activation energy and kinetic parameters of the thermal decomposition process were determined by applying the isoconversional differential method and multivariate non-linear regression method. According to TGA results, metal oxide nanofillers affected the thermal stability of PLA and caused a decrease in the activation energy values. Moreover, the fillers acted as heterogenous nucleating agents, accelerating the non-isothermal crystallization of PLA, thus reducing its activation energy. It can be concluded that metal oxide nanofillers catalytically affect the thermal degradation and crystallization of PLA samples.

In this work, the modification process of poly(lactic acid) (PLA) with metal-based nanoparticle (NPs) additives (Ag, ZnO, TiO₂) at different loading (0.5, 1.0, and 2.5 wt%) and by melt-mix extrusion method followed by film formation as one of the advantageous techniques for industrial application have been investigated. PLA nanoparticle composite films (PLA-NPs) of PLA-Ag, PLA-ZnO, PLA-TiO₂ were fabricated, allowing convenient dispersion of NPs within the PLA matrix to further pursue the challenge of investigating the surface properties of PLA-NPs reinforced plastics (as films) for the final functional properties, such as antimicrobial activity and surface mechanical properties. The main objective was to clarify how the addition of NPs to the PLA during the melt extrusion process affects the chemistry, morphology, and wettability of the surface and its further influence on the antibacterial efficiency and mechanical properties of the PLA-NPs. Therefore, the effect of Ag, ZnO, and TiO₂ NPs incorporation on the morphology (SEM), elemental mapping analysis (SEM-EDX), roughness, surface free energy (SFE) of PLA-NPs measured by goniometry and calculated by OWRK (Owens, Wendt, Rabel, and Kaelble) model was evaluated and correlated with the final functional properties such as antimicrobial activity and surface mechanical properties. The developed PLA-metal-based nanocomposites, with improved mechanical and antimicrobial surface properties, could be used as sustainable and biodegradable materials, offering desirable multifunctionalities not only for food packaging but also for cosmetics and hygiene products, as well as for broader plastic products where antimicrobial activity is desirable.

Packaging applications cover approximately 40% of the total plastics production, whereas food packaging possesses a high proportion within this context. Due to several environmental concerns, petroleum-based polymers have been shifted to their biobased counterparts. Poly(lactic acid) (PLA) has been proved the most dynamic biobased candidate as a substitute of the conventional polymers. Despite its numerous merits, PLA exhibits some limitations, and thus reinforcing agents are commonly investigated as fillers to ameliorate several characteristics. In the present study, two series of PLA-based nanocomposites filled with biobased kraft-lignin (KL) and tannin (T) in different contents were prepared. A melt–extrusion method was pursued for nanocomposites preparation. The thermal stability of the prepared nanocomposites was examined by Thermogravimetric Analysis, while thermal degradation kinetics was applied to deepen this process. Pyrolysis–Gas Chromatography/Mass Spectrometry was employed to provide more details of the degradation process of PLA filled with the two polyphenolic fillers. It was found that the PLA/lignin nanocomposites show better thermostability than neat PLA, while tannin filler has a small catalytic effect that can reduce the thermal stability of PLA. The calculated Eα value of PLA-T nanocomposite was lower than that of PLA-KL resulting in a substantially higher decomposition rate constant, which accelerate the thermal degradation.

Active packaging has played a significant role in consumers’ health and green environment over the years. Synthetic polymers, such as poly(ethylene terephthalate) (PET), polyethylene (PE), polypropylene (PP), polystyrene, poly(vinyl chloride) (PVC), polycarbonate (PC), poly(lactic acid) (PLA), etc., and naturally derived ones, such as cellulose, starch, chitosan, etc., are extensively used as packaging materials due to their broad range of desired properties (transparence, processability, gas barrier properties, mechanical strength, etc.). In recent years, the food packaging field has been challenged to deliver food products free from microbes that cause health hazards. However, most of the used polymers lack such properties. Owing to this, active agents such as antimicrobial agents and antioxidants have been broadly used as potential additives in food packaging substrates, to increase the shelf life, the quality and the safety of food products. Both synthetic active agents, such as Ag, Cu, ZnO, TiO₂, nanoclays, and natural active agents, such as essential oils, catechin, curcumin, tannin, gallic acid, etc., exhibit a broad spectrum of antimicrobial and antioxidant effects, while restricting the growth of harmful microbes. Various bulk processing techniques have been developed over the years to produce appropriate food packaging products and to add active agents on polymer matrices or on their surface. Among these techniques, extrusion molding is the most used method for mass production of food packaging with incorporated active agents into polymer substrates, while injection molding, thermoforming, blow molding, electrospinning, etc., are used to a lower extent. This review intends to study the antimicrobial and antioxidant effects of various active agents incorporated into polymeric substrates and their bulk processing technologies involved in the field of food packaging.

This research focuses on key priorities in the field of sustainable plastic composites that will lead to a reduction in CO₂ pollution and support the EU’s goal of becoming carbon neutral by 2050. The main challenge is to develop high-performance polyphenol-reinforced thermoplastic composites, where the use of natural fillers replaces the usual chemical additives with non-toxic ones, not only to improve the final performance but also to increase the desired multifunctionalities (structural, antioxidant, and antibacterial). Therefore, poly (lactic acid) (PLA) composites based on Kraft lignin (KL) and tannin (TANN) were investigated. Two series of PLA composites, PLA-KL and PLA-TANN, which contained natural fillers (0.5%, 1.0%, and 2.5% (w/w)) were prepared by hot melt extrusion. The effects of KL and TANN on the PLA matrices were investigated, especially the surface physicochemical properties, mechanical properties, and antioxidant/antimicrobial activity. The surface physicochemical properties were evaluated by measuring the contact angle (CA), roughness, zeta potential, and nanoindentation. The results of the water contact angle showed that neither KL nor TANN caused a significant change in the wettability, but only a slight increase in the hydrophilicity of the PLA composites. The filler loading, the size of the particles with their available functional groups on the surfaces of the PLA composites, and the interaction between the filler and the PLA polymer depend on the roughness and zeta potential behavior of the PLA-KL and PLA-TANN composites and ultimately improve the surface mechanical properties. The antioxidant properties of the PLA-KL and PLA-TANN composites were determined using the DPPH (2,2′-diphenyl-1-picrylhydrazyl) test. The results show an efficient antioxidant behavior of all PLA-KL and PLA-TANN composites, which increases with the filler content. Finally, the KL- and PLA-based TANN have shown resistance to the Gram-negative bacteria, E. coli, but without a correlation trend between polyphenol filler content and structure.