A new active coating was developed by using Cucumis metuliferus fruit extract as antioxidant additive with the aim of obtaining an easy way to functionalize low-density polyethylene (LDPE) films for food packaging applications. Thus, an extraction protocol was first optimized to determine the total phenolic compounds and the antioxidant activity of CM. The aqueous CM antioxidant extract was then incorporated into cellulose acetate (CA) film-forming solution in different concentrations (1, 3 and 5 wt.%) to be further coated in corona-treated LDPE to obtain LDPE/CA-CM bilayer systems. CA and CA-CM film-forming solutions were successfully coated onto the surface of LDPE, showing good adhesion in the final bilayer structure. The optical, microstructural, thermal, mechanical and oxygen barrier performance, as well as the antioxidant activity, were evaluated. The active coating casted onto the LDPE film did not affect the high transparency of LDPE and improved the oxygen barrier performance. The antioxidant effectiveness of bilayer packaging was confirmed by release studies of Cucumis metuliferus from the cellulose acetate layer to a fatty food simulant. Finally, the LDPE/CA-CM active materials were also tested for their application in minimally processed fruits, and they demonstrated their ability to reduce the oxidation process of fresh cut apples. Thus, the obtained results suggest that CA-CM-based coating can be used to easily introduce active functionality to typically used LDPE at industrial level and enhance its oxygen barrier, without affecting the high transparency, revealing their potential application in the active food packaging sector to extend the shelf-life of packaged food by prevention of lipid oxidation of fatty food or by prevention fruit browning.

This article proposes a foaming method using supercritical carbon dioxide (scCO₂) to obtain compostable bionanocomposite foams based on PLA and organoclay (C30B) where this bionanocomposite was fabricated by a previous hot melt extrusion step. Neat PLA films and PLA/C30B films (1, 2, and 3 wt.%) were obtained by using a melt extrusion process followed by a film forming process obtaining films with thicknesses between 500 and 600 μm. Films were further processed into foams in a high-pressure cell with scCO₂ under constant conditions of pressure (25 MPa) and temperature (130 °C) for 30 min. Bionanocomposite PLA foams evidenced a closed cell and uniform cell structure; however, neat PLA presented a poor cell structure and thick cell walls. The thermal stability was significantly enhanced in the bionanocomposite foam samples by the good dispersion of nanoclays due to scCO₂, as demonstrated by X-ray diffraction analysis. The bionanocomposite foams showed improved overall mechanical performance due to well-dispersed nanoclays promoting increased interfacial adhesion with the polymeric matrix. The water uptake behavior of bionanocomposite foams showed that they practically did not absorb water during the first week of immersion in water. Finally, PLA foams were disintegrated under standard composting conditions at higher rates than PLA films, showing their sustainable character. Thus, PLA bionanocomposite foams obtained by batch supercritical foaming seem to be a sustainable option to replace non-biodegradable expanded polystyrene, and they represent a promising alternative to be considered in applications such as food packaging and other products.

Microcellular nanocomposite foams functionalized with cinnamaldehyde (Ci) were obtained through two-step supercritical foaming and impregnation processing. PLA nanocomposite foams with different C30B concentrations (1, 2, and 3 wt.%) were obtained by foaming with scCO₂ at 25 MPa and 135 °C and impregnated with Ci at 12 MPa and 40 °C. The effect of the C30B content and Ci incorporation on the morphological, structural, thermal, and release properties of the developed foams were investigated. The incorporation of Ci was not influenced by C30B’s addition. The presence of C30B and Ci incorporation reduced the average pore diameter slightly and the crystallinity degree of the foams extensively. Simultaneously, the experimental and theoretical characterization of the Ci release from the PLA nanocomposite foams in EtOH 50% was analyzed. The mechanism of Ci release from the foams was defined as a quasi-Fickian diffusion process that could be successfully described using the Korsmeyer–Peppas model. The active PLA foams presented a higher potential of migration and faster release when compared with that reported in commonly used PLA films, showing that biopolymeric foams could be potentially used as active food packaging to improve the migration of active compounds with low migration potentials in order to improve their biological activity in foods.

In the last decade, among the emerging technologies in the area of bioplastics, additive manufacturing (AM), commonly referred to as 3D printing, stands out. This technology has gained great interest in the development of new products, mainly due to its capability to easily produce customized and low-cost plastic products. This work aims to evaluate the effect of supercritical foaming of 3D-printed parts based on a commercial PLA matrix loaded with calcium carbonate, for single-use sustainable food contact materials. 3D-printed PLA/CaCO₃ parts were obtained by 3D printing with a 20% and 80% infill, and two infill patterns, rectilinear and triangular, were set for each of the infill percentages selected. Supercritical fluid foaming of PLA/CaCO₃ composite printed parts was performed using a pressure of 25 MPa, a temperature of 130 °C for 23 min, with a fast depressurization rate (1 s). Closed-cell foams were achieved and the presence of CaCO₃ did not influence the surface of the foams or the cell walls, and no agglomerations were observed. Foam samples with 80% infill showed subtle temperature fluctuations, and thermogravimetric analysis showed that samples were thermally stable up to ~300 °C, while the maximum degradation temperature was around 365 °C. Finally, tensile test analysis showed that for lower infill contents, the foams showed lower mechanical performance, while the 80% infill and triangular pattern produced foams with good mechanical performance. These results emphasize the interest in using the supercritical CO₂ process to easily produce foams from 3D-printed parts. These materials represent a sustainable alternative for replacing non-biodegradable materials such as Expanded Polystyrene, and they are a promising option for use in many industrial applications, such as contact materials.

The design of biodegradable polymeric materials is of increasing scientific interest due to accelerating levels of plastics pollution. One area of increasing interest is the design of biodegradable polymer films based on seaweed as a raw material. The goal of the study is to explore whether machine learning techniques can be used to predict the properties of unknown compositions based on existing data from the literature. Clustering algorithms are used, which show how some ingredients components at certain concentration levels alter the mechanical properties of the films. Robust regression algorithms with three popular models, namely decision tree, random forest, and gradient boosting. Their predictive capabilities are compared, resulting in the random forest algorithm being the most stable with the greatest predictive capacity. These analyses offer a decision support system for biomaterials manufacturing and experimentation. The results and conclusions of the study indicate that bioplastics made from seaweed have promising potential as a sustainable alternative to traditional plastics, discovering interesting additives to improve the performance of biopolymers. In addition, the machine learning approaches used provide effective tools for analyzing and predicting the properties of these materials in structured but highly sparse data.