Biobased and biodegradable plastics have emerged as promising alternatives to conventional plastics offering the potential to reduce environmental impacts while promoting sustainability. This study focuses on the production of multilayer blown films with enhanced functional properties suitable for food packaging applications. Films were developed through co-extrusion in a three-layer film configuration, with Polybutylene Succinate (PBS) and Polybutylene Succinate Adipate (PBSA) as the external and internal layers, respectively. The functional layer consisted of Polyhydroxybutyrate (PHB) enhanced with nanoclays Cloisite^® 30B at varying weight ratios. Films were also processed by manipulating the extruder screw speed of the functional layer to investigate its impact on the functional properties. Rheology, mechanical strength, and barrier performance were characterised to establish correlations between processing conditions and functional layer blends (Cloisite^® 30B/PHB) on the properties of the resultant films. Rheological test results indicated that the system with 5% Cloisite^® had the best polymer/nanofiller matrix dispersion. Mechanical and permeability tests showed that by varying the process conditions (the alteration of the thickness of the functionalized layer) resulted in an improvement in mechanical and barrier properties. Furthermore, the addition of the nanofiller resulted in a stiffening of the film with a subsequent decrease in permeability to oxygen and water vapour.

Biodegradable polymer blends are promising materials for flexible packaging films with tunable properties. In this work, poly(butylene succinate)/poly(vinyl alcohol) (PBS/PVOH) blown films were produced by twin-screw melt compounding followed by film blowing, and the effect of PVOH content on phase organization, processability, morphology, and functional performance was investigated. The blends showed phase-separated morphologies and composition-dependent structural evolution. DSC indicated that both polymers largely retained their crystallization ability, although the crystallinity decrease was more evident for PVOH. Rheological analysis revealed limited compatibility and increasing elastic response at higher PVOH contents, consistent with the formation of structured PVOH insoluble gel-like domains. SEM confirmed droplet–matrix morphologies, becoming coarser and more heterogeneous at high PVOH content, with film-blowing instability for PBS/PVOH 20/80. PVOH incorporation improved oxygen and water-vapor barrier properties and increased stiffness, but progressively reduced ductility. Model fitting supported the structure–property correlations, relating film performance to blend composition, morphology, and PVOH phase organization. Among the processable formulations, PBS/PVOH 80/20 showed the best balance between improved barrier properties and acceptable extensibility for food packaging application. Overall, PBS/PVOH blown films are promising biodegradable systems for flexible food packaging, provided that PVOH phase structuring is properly controlled.