The demand to develop and produce eco-friendly alternatives for food packaging is increasing. The huge negative impact that the disposal of so-called “single-use plastics” has on the environment is propelling the market to search for new solutions, and requires initiatives to drive faster responses from the scientific community, the industry, and governmental bodies for the adoption and implementation of new materials. Bioplastics are an alternative group of materials that are partly or entirely produced from renewable sources. Some bioplastics are biodegradable or even compostable under the right conditions. This review presents the different properties of these materials, mechanisms of biodegradation, and their environmental impact, but also presents a holistic overview of the most important bioplastics available in the market and their potential application for food packaging, consumer perception of the bioplastics, regulatory aspects, and future challenges.

Paper-based food packaging materials are widely used, renewable, and biodegradable. Because of its porous structure, paper has poor or no barrier performance against grease, water vapor, water, and volatile organic compounds. Moreover, recycled paperboard can be a source of organic residuals that are able to migrate into packed food. Two different types of paperboard produced from primary and secondary cellulosic fibers were coated using renewable materials, such as alginate and chitosan, and comprehensive barrier measurements showed multifunctional barrier properties of these two biomaterials. Both paper substrates were successfully coated using a draw-down coater, and the measured air permeability of the coated samples was 0 mL·min⁻¹. Grease resistance was improved, while it was possible to reduce water vapor transmission, the migration of mineral oil saturated hydrocarbons and mineral oil aromatic hydrocarbons (MOSH/MOAH), and the permeation of volatile compounds for both paper substrates when compared with uncoated substrates. Wettability and water absorptiveness of chitosan- and alginate-coated papers were found to be substrate-dependent properties, and could be significantly affected by bio-based coatings. In summary, industrially produced paperboard was upgraded by coating it with the naturally biodegradable biopolymers, alginate and chitosan, thus achieving extraordinary barrier performance for various applications within the packaging industry.

The vast amount of synthetic polymers used in packaging is putting a strain on the environment and is depleting finite, non-renewable raw materials. Abundantly available biopolymers such as alginate, chitosan and microfibrillated cellulose (MFC) have frequently been suggested in the literature to replace synthetic polymers and their barrier properties have been investigated in detail. Many studies aim to improve the properties of standalone biopolymer films. Some studies apply these biopolymers as barrier coatings on paper, but the solids content in most of these studies is quite low, which in turn would result in a high energy demand in industrial drying processes. The aim of this study is to suggest a laboratory procedure to investigate the suitability of these biopolymers at higher and such more industrially relevant solids content as potential coating materials for paper and board in order to improve their barrier properties. First, biopolymer solutions are prepared at a high solids content at which the viscosity at industrially relevant higher shear rates of 50,000 s⁻¹ (1000 s⁻¹ for MFC) is in the same range as a synthetic reference material (in this case ethylene vinyl alcohol EVOH) at 10 wt%. These solutions are analyzed regarding properties such as rheology and surface tension that are relevant for their coatability in industrial coating processes. Then, free-standing films are cast, and the films are characterized regarding important properties for packaging applications such as different surface, mechanical and barrier properties. Based on these results suitable biopolymers for future coating trials can be easily identified.

Chitosan is a versatile biopolymer with many interesting functionalities. Its effects on the barrier and mechanical properties of single- or double-coated fibre-based packaging papers in dependence on the applied drying regime were successfully tested. Our investigations revealed chitosan to be a highly robust biopolymer, since the different drying regimes did not alter its contribution to the development of strength and barrier properties of the coated packaging papers. These properties showed a stronger influence of the applied coat weights than of the different drying regimes. The effect of chitosan coatings were quantified by measuring tensile strength (TS), burst strength (BS) and tensile energy absorption (TEA). These revealed that TS, BS and TEA of the coated papers increased significantly. Moreover, the chitosan-coated papers were less permeable against water vapor and air. High grease resistance was observed for double-coated papers, irrespective of the drying regimes. The coated paper surface showed a more hydrophilic character, resulting in lower contact angles and higher water absorption properties. In this study, industrially produced chitosan has been proven to be a renewable, robust biopolymer that can be utilized as an additive to increase strength and the barrier properties of fibre-based materials.

The current demand to cut back on the use of plastic materials has brought a major boost to the search for bio-based alternatives. Not only are plastic bags and primary food packaging under scrutiny here, but also those materials used as functional barriers to reduce, for example, the migration of mineral oil hydrocarbons (MOH) from recycled paper and board packaging. Most of the barriers now in use are synthetic, often have only moderate barrier functionalities and in addition reduce the environmentally-friendly character of cellulose-based materials. Against this background, bio-based polymers have been evaluated in terms of their functional barrier properties. Chitosan was found to be among the best performers in these materials. In this study, the behavior of a lab-made chitosan acetate film was compared with conventionally produced polymer films. The two-sided migration experiment described recently was used to determine the barrier properties of the tested materials. This not only allowed to test the intrinsic migration of the films and the permeation through them, but also to simulate real packaging situations by using a recycled paper as donor for MOH. The migrated fractions were determined using gas-chromatography-based techniques. While the conventionally produced polymer films showed only moderate barrier function, excellent results were seen for the biopolymer. It reduced the migration from the recycled paper to not detectable, singling it out as a good alternative to conventional materials.