Optimization of Laminated Bio-Polymer Fabrication for Food Packaging Application: A Sustainable Plasma-Activated Approach

: The current level of packaging consumption imposes a need to fabricate single-use food packaging with renewable and compostable materials, such as bio-polyesters (e.g., polylactic acid, PLA and polybutylene succinate, PBS) or cellulose, but their use is still problematic. Fabrication of bio-compostable composites can specifically address impeding challenges, and adhesive lamination, achieved with compostable glue, is becoming more and more popular with respect to the less versatile hot lamination. In this context, plasma activation, a chemical-free oxidation technique of a material's surface, is used to increase the affinity of three different biomaterials (cellulose, PLA and PBS) toward a compostable polyurethane adhesive to decrease its amount by gluing bio-polyesters to cellulose. Optical Microscopy reveals activation conditions that do not affect the integrity of the materials, while Water Contact Analyses confirm the activation of the surfaces, with contact angles decreased to roughly 50 deg in all cases. Unexpectedly, ζ-potential analyses and subtractive infrared spectroscopy highlight how the activation performed superficially etches cellulose, while for both PLA and PBS, a general decrease in surface potential and an increase in superficial hydroxyl group populations confirm the achievement of the desired oxidation. Thus, we rationalize continuous activation conditions to treat PLA and PBS and to glue them to neat cellulose. While no beneficial effect is observed with activated PLA, bi-laminate composites fabricated with activated PBS fulfill the benchmark for adhesion strength using less than before, while oxygen permeation analyses exclude plasma-induced etching even at a nanoscale.