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.

Expanded polystyrene will account for 5.3% of total global plastic production in 2021 and is widely used for food packaging due to its excellent moisture resistance and thermal insulation. However, some of these packages are often used only once before being discarded, generating large amounts of environmentally harmful plastic waste. A very attractive alternative to the conventional methods used for polymer processing is the use of supercritical carbon dioxide (scCO₂) since it has mass-transfer properties adapted to the foam morphology, generating different path lengths for the diffusion of active compounds within its structure and can dissolve a wide range of organic molecules under supercritical conditions. The objective of this research was to evaluate the effect of operational variables on the process of caffeic acid (CA) impregnation and subsequent foaming of polylactic acid (PLA) as well as two PLA/poly(butylene-co-terephthalate-adipate) (PBAT) blends using scCO₂. The results showed an increase in the degree of crystallinity of the CA-impregnated samples due to the nucleation effect of the active compound. On the other hand, SEM micrographs of both films and foams showed significant differences due to the presence of PBAT and its low miscibility with PLA. Finally, the results obtained in this work contribute to the knowledge of the important parameters to consider for the implementation of the impregnation and foaming process of PLA and PLA/PBAT blends with potential use in food packaging.

Conventional techniques for incorporating active ingredients into polymeric matrices are accompanied by certain disadvantages, primarily attributable to the inherent characteristics of the active ingredient itself, including its sensitivity to temperature. A potential solution to these challenges lies in the utilization of supercritical carbon dioxide (scCO₂) for the formation of polymeric foam and the incorporation of active ingredients, in conjunction with the encapsulation of inclusion complexes (ICs), to ensure physical stability and augmented bioactivity. The objective of this study was to assess the impact of IC impregnation and subsequent foam formation on PLA films and PLA/PBAT blends that had been previously impregnated. The study’s methodology encompassed the formation and characterization of ICs with caffeic acid (CA) and β-cyclodextrin (β-CD), along with the thermal, structural, and morphological properties of the resulting materials. Higher incorporation of impregnated IC into the PLA(42)/PBAT(58) blend was observed at 12 MPa pressure and a depressurization rate of 1 MPa/min. The presence of IC, in addition to a lower rate of expansion, contributed to the formation of homogeneous cells with a size range of 4–44 um. On the other hand, the incorporation of IC caused a decrease in the crystallinity of the PLA fraction due to the interaction of the complex with the polymer. This study makes a significant contribution to the advancement of knowledge on the incorporation of compounds encapsulated in β-CD by scCO₂, as well as to the development of active materials with potential applications in food packaging.