Bio-based and biodegradable polyhydroxyalkanoates (PHAs) have great potential as sustainable packaging materials. The incorporation of zinc oxide nanoparticles (ZnO NPs) could further improve their functional properties by providing enhanced barrier and antimicrobial properties, although current literature lacks details on how the characteristics of ZnO influence the structure-property relationships in PHA/ZnO nanocomposites. Therefore, commercial ZnO NPs with different morphologies (rod-like, spherical) and silane surface modification are incorporated into poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBHHx) via extrusion and compression molding. All ZnO NPs are homogeneously distributed in the PHBHHx matrix at 1, 3 and 5 wt.%, but finer dispersion is achieved with modified ZnO. No chemical interactions between ZnO and PHBHHx are observed due to a lack of hydroxyl groups on ZnO. The fabricated nanocomposite films retain the flexible properties of PHBHHx with minimal impact of ZnO NPs on crystallization kinetics and the degree of crystallinity (53 to 56%). The opacity gradually increases with ZnO loading, while remaining translucent up to 5 wt.% ZnO and providing an effective UV barrier. Improved oxygen barrier and antibacterial effects against S. aureus are dependent on the intrinsic characteristics of ZnO rather than its morphology. We conclude that PHBHHx retains its favorable processing properties while producing nanocomposite films that are suitable as flexible active packaging materials.

While near-infrared (NIR) spectroscopy in post-consumer waste electrical and electronic equipment (WEEE) recycling accurately separates white or clear polymers, 40% containing dark plastics, termed \'unsortable WEEE,\' are excluded from sorting lines and therefore incinerated or landfilled, causing environmental concerns. This study investigates the potential of using non-reactive and reactive copolymers as compatibilizers to enhance the performance of unsortable WEEE plastics free of brominated flame retardants. To the best of our knowledge, this is the first time that such copolymers have been explored as a solution for improving the compatibility of unsortable WEEE polymer blends. Initial trials with 4% of styrene-ethylene-butylene-styrene copolymer (SEBS-13) and SEBS-30-g-(maleic anhydride) copolymer (SEBS-30-g-MA MA) as compatibilizers showed insufficient results compared to virgin commercial polymers. However, the addition of higher concentrations of compatibilizers (i.e. up to 20 wt%) and the use of a SEBS having a higher styrene content (i.e. SEBS-30) improved the mechanical properties of the material, causing it to transition from brittle to ductile. This behavior was found more pronounced for the 20% non-reactive SEBS-30, for which the SEM analysis showed reduced phase segregation and revealed a more homogeneous fracture surface. This was further supported by Differential Scanning Calorimetry (DSC) analysis, which showed evidence of an interaction between one or more polymer phases. With a room temperature performance equivalent to that of virgin conventional polymers, the SEBS-30 compatibilization approach has made it possible to consider using unsortable WEEE streams as recycled materials in commercial applications.

Melt processing is an emerging production method to efficiently encapsulate proteins into polymeric devices for sustained release. In the context of vaccines, melt processing is well-suited to develop vaccine delivery devices that are stable outside the cold chain and can generate protective immunity from a single dose. We have demonstrated the compatibility of bacteriophage Qβ virus-like particles (VLPs) with hot-melt extrusion (HME) and have leveraged this technology to develop a single-dose vaccine candidate for vaccination against human papillomavirus (HPV). Here, we detail the methods for chemically conjugating an HPV peptide epitope from the L2 minor capsid protein to Qβ VLPs to generate HPV-Qβ particles. We outline techniques used to characterize HPV-Qβ particles, and we elaborate on the process to encapsulate HPV-Qβ into biodegradable poly(lactic-co-glycolic acid) (PLGA) implants and discuss methods for the materials characterization of the HPV-Qβ/polymer melts. The methods described could be adapted to other disease targets, i.e., by conjugation of a different peptide epitope, or transferred to other VLP systems suited for conjugation, immune response, or stability during processing. Such VLPs are ideally suited for use in HME, a mature, scalable, continuous, and solvent-free process which can be adapted to mold devices, therefore allowing the processing of the melts into various geometries, such as subcutaneous implants, or self-administrable microneedle patches.

This review paper presents an overview of the state of the art on process-induced degradation of poly(lactic acid) (PLA) and the relative importance of different processing variables. The sensitivity of PLA to degradation, especially during melt processing, is considered a significant challenge as it may result in deterioration of its properties. The focus of this review is on degradation during melt processing techniques such as injection molding and extrusion, and therefore it does not deal with biodegradation. Firstly, the general processing and fundamental variables that determine the degradation are discussed. Secondly, the material properties (for example rheological, thermal, and mechanical) are presented that can be used to monitor and quantify the degradation. Thirdly, the effects of different processing variables on the extent of degradation are reviewed. Fourthly, additives are discussed for melt stabilization of PLA. Although current literature reports the degradation reactions and clearly indicates the effect of degradation on PLA\'s properties, there are still knowledge gaps in how to select and predict the processing conditions that minimize process-induced degradation to save raw materials and time during production.

Paramylon is a linear β-1,3-glucan produced by the microalgae Euglena Gracilis. Due to its native crystalline structure, involving hexagonally packed triple helices, paramylon is neither water soluble nor thermoplastic. While such properties are generally obtained by chemical modification of paramylon, the present work demonstrates that using ionic liquid/water mixtures as solvents or plasticizers may be an alternative: A mixture of water with cholinium glycinate (40:60) allowed: i) obtaining paramylon solutions at 80 °C, that form reversible ionogels upon cooling at 20 °C, when used as a solvent, and ii) the thermomechanical processing of paramylon below 100 °C by extrusion and hot-press into transparent films, when used as a plasticizer. The thermoplastic paramylon obtained consists of an amorphous matrix, self-reinforced by oriented triple helices packed as nanofibers. This results in a storage modulus ranging from 300 to 450 MPa at 25 °C, depending on the plasticizer content, and in a tensile strain at break of 27 %. For storage times larger than 1 month, a recrystallization of paramylon is observed, with an unidentified crystalline structure different from the native one. Recrystallized samples can be reprocessed into amorphous films by hot pressing.

The aim of this study was to obtain biocomposites consisting of poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), bacterial cellulose (BC) and α-tocopherol by a melt processing technique for potential use in biomedical applications. The melt processing and roughness of biocomposites were evaluated and compared to sample without BC. The degradation rate of PHBV/BC biocomposites was measured in phosphate buffer saline (PBS) by determining the mass variation and evidencing of thermal and structural changes by differential scanning calorimetry (DSC) and attenuated total reflectance-Fourier transformed infrared spectrometry (ATR-FTIR). The cell viability, cell morphology, cell cycle distribution and total collagen content were investigated on murine NCTC fibroblasts. Overall, the adding of BC to polyester matrix led to an adequate melt processing of biocomposites and increased surface roughness and cytocompatibility, allowing the cells to secrete the extracellular matrix (collagen) and stimulate cell proliferation. Results showed that the PHBV/BC biocomposites were favorable for long-term degradation and could be used for the design of medical devices with controlled degradability.

In the quest to develop sustainable and environmentally friendly materials, cellulose is a promising alternative to synthetic polymers. However, native cellulose, in contrast to many synthetic polymers, cannot be melt-processed with traditional techniques because, upon heating, it degrades before it melts. One way to improve the thermoplasticity of cellulose, in the form of cellulose fibers, is through chemical modification, for example, to dialcohol cellulose fibers. To better understand the importance of molecular interactions during melt processing of such modified fibers, we undertook a molecular dynamics study of dialcohol cellulose nanocrystals with different degrees of modification. We investigated the structure of the nanocrystals as well as their interactions with a neighboring nanocrystal during mechanical shearing, Our simulations showed that the stress, interfacial stiffness, hydrogen-bond network, and cellulose conformations during shearing are highly dependent on the degree of modification, water layers between the crystals, and temperature. The melt processing of dialcohol cellulose with different degrees of modification and/or water content in the samples was investigated experimentally by fiber extrusion with water used as a plasticizer. The melt processing was easier when increasing the degree of modification and/or water content in the samples, which was in agreement with the conclusions derived from the molecular modeling. The measured friction between the two crystals after the modification of native cellulose to dialcohol cellulose, in some cases, halved (compared to native cellulose) and is also reduced with increasing temperature. Our results demonstrate that molecular modeling of modified nanocellulose fibers can provide fundamental information on the structure-property relationships of these materials and thus is valuable for the development of new cellulose-based biomaterials.

Innovative composites based on polypropylene waste impurified cu HDPE (PPW) combined with two thermoplastic block-copolymers, namely styrene-butadiene-styrene (SBSBC) and styrene-isoprene-styrene (SISBC) block-copolymers, and up to 10 wt% nano-clay, were obtained by melt blending. SBSBC and SISBC with almost the same content of polystyrene (30 wt%) were synthesized by anionic sequential polymerization and used as compatibilizers for PPW. Optical microscopy evaluation of the PPW composites showed that the n-clay was encapsulated into the elastomer. Addition of n-clay, together with SBSBC or SISBC, increased the interphase surface of the components in the PPW composites and enhanced the superficial area/volume ratio, which led to a recycled material with improved performance. The data resulting from differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), mechanical evaluation, and dynamic mechanical analysis (DMA) revealed that PPW reinforcement with n-clay and styrene-diene block-copolymers allows the obtaining of composites with favorable mechanical and thermal properties, and excellent impact strength for potential engineering applications.

Hydrophobization of hemicellulose causes melt processing and makes them stretchable thermoplastics. Understanding how native and/or appended side chains in various hemicelluloses after chemical modification affect melt processing and material properties can help in the development of products for film packaging and substrates for stretchable electronics applications. Herein, we describe a one-step and two-step strategy for the fabrication of flexible and stretchable thermoplastics prepared by compression molding of two structurally different arabinoxylans (AX). For one-step synthesis, the n-butyl glycidyl ether epoxide ring was opened to the hydroxyl group, resulting in the introduction of alkoxide side chains. The first step in the two-step synthesis was periodate oxidation. Because the melt processability for AXs having low arabinose to xylose ratio (araf/xylp<0.5) have been limited, two structurally distinct AXs extracted from wheat bran (AXWB, araf/xylp = 3/4) and barley husk (AXBH, araf/xylp = 1/4) were used to investigate the effect of araf/xylp and hydrophobization on the melt processability and properties of the final material. Melt compression processability was achieved in AXBH derived samples. DSC and DMA confirmed that the thermoplastics derived from AXWB and AXBH had dual and single glass transition (Tg) characteristics, respectively, but the thermoplastics derived from AXBH had lower stretchability (maximum 160%) compared to the AXWB samples (maximum 300%). Higher araf/xylp values, and thus longer alkoxide side chains in AXWB-derived thermoplastics, explain the stretchability differences.

Biobased and biodegradable polyhydroxyalkanoates (PHAs) have great potential as sustainable packaging materials. However, improvements in their processing and mechanical properties are necessary. In this work, the influence of melt processing conditions on the mechanical properties and microstructure of poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBHHx) is examined using a full factorial design of experiments (DoE) approach. We have found that strict control over processing temperature, mold temperature, screw speed, and cooling time leads to highly increased elongation at break values, mainly under influence of higher mold temperatures at 80 °C. Increased elongation of the moldings is attributed to relaxation and decreased orientation of the polymer chains together with a homogeneous microstructure at slower cooling rates. Based on the statistically substantiated models to determine the optimal processing conditions and their effects on microstructure variation and mechanical properties of PHBHHx samples, we conclude that optimizing the processing of this biopolymer can improve the applicability of the material and extend its scope in the realm of flexible packaging applications.