Usage of non-biodegradable materials for the
various packaging applications has raised environmental pollution concerns. Food
packaging accounts for the biggest growing sector within the synthetic plastic
packaging market domain. Large amounts of different materials, like
paper, glass and plastics, are used globally to manufacture packaging materials
and more than two thirds are used in the food sector alone. This amount is
growing unceasingly as a result of changes occurring in habits of food
preparation and consumption, as well as the positive development of various
areas and markets in the world. The packaging industry consumes the highest
volumes of plastics produced globally and is the main source supplying waste
plastics into the environment at an alarming rate. This can be attributed to
single use plastics and the increase of on the go snacks and readymade meals
that imply the once-off use of durable plastic packaging material. As a result,
there is increasing need for eco-friendly sustainable packaging materials with
the desired physical, mechanical and barrier properties for food packaging.
Biodegradable Food Packaging
The food packaging industry is now in pursuit
of biodegradable packaging that is lightweight
for reducing materials use, waste and as well as transportation costs.
Plastics from biopolymers are promising to fulfill this requirement.
Biodegradation is a process of defragmentation, initiated by heat, moisture,
and/or microbial enzymes, which transforms larger molecular substances into smaller
compounds. It can also be simply defined as a process by which substances are
broken down by living organisms.
Due to the increasing environmental concerns
created by excessive plastic accumulation, interest has shifted towards the
development of such packaging materials that not only improve performance but
are also easy to recycle and reuse i.e., “bio-plastics”. According to the European Bioplastics
organization, bioplastics can be defined as plastics based on renewable
resources or as plastics which are biodegradable and/or compostable polymers.
Bioplastics are derived from different renewable sources such as vegetable oil,
corn starch, potato starch, fibers obtained from pineapple, jute, hemp,
henequen leaves and banana stems and also from used plastic bottles and other
containers using microorganisms.
Natural polymers or polymers derived from biomass
The natural polymers are derived from animal,
marine, and agricultural sources, which include the polysaccharides, such as
starch, cellulose, chitosan, gums etc., proteins like plant derived proteins
(zein, gluten, soy, etc.) and animal extracted proteins (casein, collagen,
gelatin, etc.) and lipids including cross linked triglycerides. By nature most
of these polymers are hydrophilic and crystalline in nature, which create
several problems while processing in moist food packaging. However they have
excellent gas barrier properties which make them acceptable for their
utilization in food packaging.
a) Starch:
Starch
is the most abundant commonly used renewable raw material and easy
biodegradable natural resource. It is obtained from seeds, corn, wheat, rice,
potato, sweet potato, and cassava. Starch is usually used as a thermoplastic
and constitutes a substitute for polystyrene (PS). It is plasticized through
destructuration in presence of specific amounts of water or plasticizers
(glycerol, sorbitol) and heat and then it is extruded. Starch is an attractive
material for packaging applications because of its relatively low cost,
availability, and biodegradability. Starch having poor resistance to moisture
and their poor mechanical property restricts their use. Therefore to improve
these properties starch is blended with various biopolymers and certain
additives.
b) Cellulose:
Cellulose is the most abundant natural polymer and is derived by a
delignification from wood pulp or cotton linters. Cellulose is very difficult
to use in packaging because it is hydrophilic and crystalline in nature
possessing poor mechanical properties in its raw form. Therefore, it must be
treated with chemicals like NaOH, H2SO4, CS2, etc. to produce cellophane having
excellent mechanical characteristics. Cellulose derivatives can be produced by
derivatization of cellulose from the solvated state, via esterification or
etherification of hydroxyl group. Cellulose derivative forms are used for films
or edible coatings are Hydroxypropyl cellulose, hydroxypropyl methylcellulose,
Carboxymethyl cellulose or Methyl cellulose.
Incorporation of hydrophobic compounds is one method for increasing the
moisture barrier, such as fatty acids into the cellulose ether matrix to
develop a composite film.
c) Chitosan
or chitin: Chitosan or chitin, is the second abundant
polysaccharides resource after cellulose found in nature. It naturally appears
in the exoskeleton of arthropods and in the cell walls of yeasts and fungi. It
is produced commercially by chemical extraction processes from prawns and crabs
wastes. Chitosan is obtained from deacetylation of chitin, and different
factors (e.g. alkali concentration, incubation time, and chitin to alkali ratio,
temperature and chitin source) can affect its properties. Chitosan forms films
without the addition of additives, exhibits good carbon dioxide and oxygen
permeability, as well as excellent mechanical properties and antimicrobial
properties which reduces the oxidation process and is beneficial for increasing
the shelf life and quality of food products.
d) Proteins: Proteins
are complex structures made up of amino acids and can be obtained from plant
(wheat gluten, corn, zein, soy protein etc.) and animal (casein, whey, keratin,
gelatin, etc.) sources. They are highly desirable to modify the required
characteristics of packaging materials due to the presence of unique side chain
in their structure. Due to the renewable nature, biodegradability and their
excellent gas barrier properties proteins and protein based materials find
their use in many industrial applications. But they are adversely affected by
their hydrophilic nature like starch-based polymers. Therefore, they need to be
blended with other polymers or must be chemically or micro-biologically
modified.
i.
Casein is a milk derived protein, when
processed with suitable plasticizers at temperature of 80-100 0C,
form materials with mechanical performance varying from stiff and brittle to
flexible and tough performance. Casein films have an opaque appearance.
Irrespective of its relatively high price, it is used today for bottle labeling
because of its excellent adhesive properties.
ii. Gluten
plastics exhibit high gloss and show good moisture resistance under certain
conditions. They do not dissolve in water, but absorb some water on immersion.
iii. Soya
proteins are commercially available as soya flour, soya concentrate and soya
isolate. Soya protein isolate (SPI) may be used to prepare edible and
biodegradable packaging films. The films obtained from SPI exhibit excessive
friability, so their performance is limited. In order to improve them, they
must be modified by the addition of a plasticizer, such as glycerol.
The cheapest protein, keratin extracted from
waste streams such as hair, nails and feathers. Keratin the most difficult
protein to process due to its structure and a high content of cysteine groups.
On the other hand, whey proteins, byproducts from the cheese industry, are
widely employed as edible films and coatings. Several lipid components like
fatty acids, natural waxes, resins and vegetable oils are generally
incorporated in the films to provide hydrophobicity so that moisture barrier
properties can be improved.
Synthetic
polymers
They
are produced from classical chemical synthesis from bio-based monomers. In this
category, polylactic acid (PLA) is one of the most commercially available and
exploited bioplastics.
a) Polylatic acid (PLA): PLA one of the most promising and biodegradable polyester made from
renewable resources such as corn, sugar beets, and potato starch for commercial
use as a substitute for high density polyethylene (HDPE) and low density
polyethylene (LDPE), polystyrene (PS) and polyethylene terephthalate (PET). It
is obtained by conversion of corn, or other carbohydrate sources, into
dextrose, followed by fermentation into lactic acid. Through direct
polycondensation of lactic acid monomers or through ring-opening polymerization
of lactide, PLA pellets are obtained. The processing possibilities of this
transparent material are very vast, ranging from injection molding and
extrusion over cast film extrusion to blow molding and thermoforming. PLA is
becoming an advancing alternative as a green food packaging material because it
was found that in many circumstances its performance was better than synthetic
plastic materials. PLA comes in the form of films, thermo-formed cups and
trays, containers and coatings for paper and paper boards etc.
Applications of
bioplastics in food packaging
Among
the extensively used bio-based plastics, PLA is widely used. Moreover, the
bioplastics nowadays have found applications for both short-shelf life products
like fresh fruits and vegetables and long shelf life products, like potato
chips and pasta.